Computerized system and method for generating an undesirable chatter free milling cnc program for use in machining a workpiece

ABSTRACT

A computerized method of machining a workpiece including, prior to machining the workpiece, establishing, based on empirical data obtained from machining activity at an earlier time, an historical mapping indicating pairings of depth of cut and rpm at which undesirable chatter (UDC) did not occur during machining activity at an earlier time using at least one given type of milling machine, at least one given type of cutting tool and at least one given type of workpiece material, prior to commencing machining of the workpiece, programming a machine tool to machine the workpiece using a given type of milling machine, a given type of cutting tool and a given type of workpiece material at at least one depth of cut and rpm, which, based on the historical mapping, avoid UDC and operating the machine tool in accordance with the programming to machine the workpiece.

FIELD OF THE INVENTION

The present invention relates to systems and methods for millingworkpieces and for generating milling CNC programs which avoidundesirable chatter (UDC).

BACKGROUND OF THE INVENTION

There are known various techniques for avoiding undesirable chatter(UDC).

SUMMARY OF THE INVENTION

The present invention seeks to provide systems and methods for millingworkpieces and for generating milling CNC programs which avoidundesirable chatter (UDC).

There is thus provided in accordance with a preferred embodiment of thepresent invention a computerized method of machining a workpieceincluding prior to machining the workpiece, establishing, based onempirical data obtained from machining activity at an earlier time, anhistorical mapping indicating pairings of depth of cut and rpm at whichundesirable chatter (UDC) did not occur during machining activity at anearlier time using at least one given type of milling machine, at leastone given type of cutting tool and at least one given type of workpiecematerial, prior to commencing machining of the workpiece, programming amachine tool to machine the workpiece using one of the at least onegiven type of milling machine, one of the at least one given type ofcutting tool and one of the at least one given type of workpiecematerial at at least one depth of cut and rpm, which, based on thehistorical mapping, avoid undesirable chatter and operating the machinetool in accordance with the programming to machine the workpiece.

Preferably, the programming includes employing known pairings of depthof cut and rpm, which are known from the historical mapping for thegiven type of milling machine, the given type of cutting tool and thegiven type of workpiece material to not create UDC for the at least onegiven type of milling machine, the at least one given type of cuttingtool and the at least one given type of workpiece material, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.

In accordance with a preferred embodiment of the present invention theprogramming includes employing pairings of depth of cut and rpm, whichare known from the historical mapping for the given type of millingmachine, the given type of cutting tool and the given type of workpiecematerial to be within a predetermined neighborhood of known pairingsknown not to create UDC and not to be within a predeterminedneighborhood of known pairings known to create UDC for the at least onegiven type of milling machine, the at least one given type of cuttingtool and the at least one given type of workpiece material, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.

In accordance with a preferred embodiment of the present invention theprogramming includes employing known pairings of depth of cut and rpm,which are known from the historical mapping for the given type ofmilling machine, the given type of cutting tool and the given type ofworkpiece material to create UDC and known pairings of depth of cut andrpm, which are known from the historical mapping for the given type ofmilling machine, the given type of cutting tool and the given type ofworkpiece material not to create UDC, in order to ascertain a suitablerpm for a given depth of cut which will not create UDC.

Preferably, the suitable rpm for the given depth of cut need notcorrespond to one of the known pairings. Alternatively, the suitable rpmfor the given depth of cut does not correspond to one of the knownpairings.

In accordance with a preferred embodiment of the present invention theprogramming includes initially generating an initial CNC program formachining the workpiece without necessarily considering UDC issues, theinitial CNC program including at least one proposed pairing of depth ofcut and rpm for at least one given type of milling machine, at least onegiven type of cutting tool and at least one given type of workpiecematerial and validating the at least one proposed pairing, based on thehistorical mapping.

In accordance with a preferred embodiment of the present invention theprogramming includes initially generating an initial CNC program formachining the workpiece without necessarily considering UDC issues, theinitial CNC program including at least one proposed pairing of depth ofcut and rpm for at least one given type of milling machine, at least onegiven type of cutting tool and at least one given type of workpiecematerial, disallowing at least one of the at least one proposed pairing,based on the historical mapping, generating at least one revised CNCprogram for machining the workpiece based on the historical mapping, theinitial CNC program including at least one alternative proposed pairingof depth of cut and rpm for at least one given type of milling machine,at least one given type of cutting tool and at least one given type ofworkpiece material and validating the at least one revised proposedpairing, based on the historical mapping.

There is also provided in accordance with another preferred embodimentof the present invention a computerized method of controlling operationof a machine tool in machining a workpiece including prior to machiningthe workpiece, establishing, based on empirical data obtained frommachining activity at an earlier time, an historical mapping indicatingpairings of depth of cut and rpm at which undesirable chatter (UDC) didnot occur during machining activity at an earlier time using at leastone given type of milling machine, at least one given type of cuttingtool and at least one given type of workpiece material and prior tocommencing machining of the workpiece, programming a machine tool tomachine the workpiece using one of the at least one given type ofmilling machine, one of the at least one given type of cutting tool andone of the at least one given type of workpiece material at at least onedepth of cut and rpm, which, based on the historical mapping, avoidundesirable chatter. Preferably, the programming includes employingknown pairings of depth of cut and rpm, which are known from thehistorical mapping for the given type of milling machine, the given typeof cutting tool and the given type of workpiece material to not tocreate UDC for the at least one given type of milling machine, the atleast one given type of cutting tool and the at least one given type ofworkpiece material, in order to ascertain a suitable rpm for a givendepth of cut which will not create UDC.

In accordance with a preferred embodiment of the present invention theprogramming includes employing pairings of depth of cut and rpm, whichare known from the historical mapping for the given type of millingmachine, the given type of cutting tool and the given type of workpiecematerial to be within a predetermined neighborhood of known pairingsknown not to create UDC and not to be within a predeterminedneighborhood of known pairings known to create UDC for the at least onegiven type of milling machine, the at least one given type of cuttingtool and the at least one given type of workpiece material, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.

Preferably, the programming includes employing known pairings of depthof cut and rpm, which are known from the historical mapping for thegiven type of milling machine, the given type of cutting tool and thegiven type of workpiece material to create UDC and known pairings ofdepth of cut and rpm, which are known from the historical mapping forthe given type of milling machine, the given type of cutting tool andthe given type of workpiece material not to create UDC, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.

In accordance with a preferred embodiment of the present invention theprogramming includes the suitable rpm for the given depth of cut neednot correspond to one of the known pairings.

Preferably, the suitable rpm for the given depth of cut does notcorrespond to one of the known pairings.

In accordance with a preferred embodiment of the present invention theprogramming includes initially generating an initial CNC program formachining the workpiece without necessarily considering UDC issues, theinitial CNC program including at least one proposed pairing of depth ofcut and rpm for at least one given type of milling machine, at least onegiven type of cutting tool and at least one given type of workpiecematerial and validating the at least one proposed pairing, based on thehistorical mapping.

Preferably, the programming includes initially generating an initial CNCprogram for machining the workpiece without necessarily considering UDCissues, the initial CNC program including at least one proposed pairingof depth of cut and rpm for at least one given type of milling machine,at least one given type of cutting tool and at least one given type ofworkpiece material, disallowing at least one of the at least oneproposed pairing, based on the historical mapping, generating at leastone revised CNC program for machining the workpiece based on thehistorical mapping, the initial CNC program including at least onealternative proposed pairing of depth of cut and rpm for at least onegiven type of milling machine, at least one given type of cutting tooland at least one given type of workpiece material and validating the atleast one revised proposed pairing, based on the historical mapping.

There is further provided in accordance with yet another preferredembodiment of the present invention a computerized system for machininga workpiece, the system including an historic mapping generatoroperative, prior to machining the workpiece, to generate an historicalmapping, based on empirical data obtained from machining activity at anearlier time, indicating pairings of depth of cut and rpm at whichundesirable chatter (UDC) did not occur during machining activity at anearlier time using at least one given type of milling machine, at leastone given type of cutting tool and at least one given type of workpiecematerial, a computerized machine tool programmer operative, prior tocommencing machining of the workpiece, to generate a machine toolprogram enabling a machine tool to machine the workpiece using one ofthe at least one given type of milling machine, one of the at least onegiven type of cutting tool and one of the at least one given type ofworkpiece material at at least one depth of cut and rpm, which, based onthe historical mapping, avoid undesirable chatter and a machine tooloperable in accordance with the programming to machine the workpiece.

Preferably, the computerized machine tool programmer includes a suitabledepth of cut and rpm ascertainer, employing known pairings of depth ofcut and rpm, which are known from the historical mapping for the giventype of milling machine, the given type of cutting tool and the giventype of workpiece material to not create UDC for the at least one giventype of milling machine, the at least one given type of cutting tool andthe at least one given type of workpiece material, in order to ascertaina suitable rpm for a given depth of cut which will not create UDC.

In accordance with a preferred embodiment of the present invention thecomputerized machine tool programmer includes a suitable depth of cutand rpm ascertainer, employing pairings of depth of cut and rpm, whichare known from the historical mapping for the given type of millingmachine, the given type of cutting tool and the given type of workpiecematerial to be within a predetermined neighborhood of known pairingsknown not to create UDC and not to be within a predeterminedneighborhood of known pairings known to create UDC for the at least onegiven type of milling machine, the at least one given type of cuttingtool and the at least one given type of workpiece material, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.

Preferably, the computerized machine tool programmer includes a suitabledepth of cut and rpm ascertainer, employing known pairings of depth ofcut and rpm, which are known from the historical mapping for the giventype of milling machine, the given type of cutting tool and the giventype of workpiece material to create UDC and known pairings of depth ofcut and rpm, which are known from the historical mapping for the giventype of milling machine, the given type of cutting tool and the giventype of workpiece material not to create UDC, in order to ascertain asuitable rpm for a given depth of cut which will not create UDC.

In accordance with a preferred embodiment of the present invention thesuitable rpm for the given depth of cut need not correspond to one ofthe known pairings.

In accordance with a preferred embodiment of the present invention thesuitable rpm for the given depth of cut does not correspond to one ofthe known pairings.

Preferably, the computerized machine tool programmer includes an initialCNC program generator, initially generating an initial CNC program formachining the workpiece without necessarily considering UDC issues, theinitial CNC program including at least one proposed pairing of depth ofcut and rpm for at least one given type of milling machine, at least onegiven type of cutting tool and at least one given type of workpiecematerial and a proposed pairing validator, validating the at least oneproposed pairing, based on the historical mapping.

In accordance with a preferred embodiment of the present invention thecomputerized machine tool programmer includes an initial CNC programgenerator, initially generating an initial CNC program for machining theworkpiece without necessarily considering UDC issues, the initial CNCprogram including at least one proposed pairing of depth of cut and rpmfor at least one given type of milling machine, at least one given typeof cutting tool and at least one given type of workpiece material, aproposed pairing disallower, disallowing at least one of the at leastone proposed pairing, based on the historical mapping, a revised CNCprogram generator, generating at least one revised CNC program formachining the workpiece based on the historical mapping, the initial CNCprogram including at least one alternative proposed pairing of depth ofcut and rpm for at least one given type of milling machine, at least onegiven type of cutting tool and at least one given type of workpiecematerial and a revised proposed pairing validator, validating the atleast one revised proposed pairing, based on the historical mapping.

There is even further provided in accordance with still anotherpreferred embodiment of the present invention a computerized system forcontrolling the machining of a workpiece, the system including anhistoric mapping generator operative, prior to machining the workpiece,to generate an historical mapping, based on empirical data obtained frommachining activity at an earlier time, indicating pairings of depth ofcut and rpm at which undesirable chatter (UDC) did not occur duringmachining activity at an earlier time using at least one given type ofmilling machine, at least one given type of cutting tool and at leastone given type of workpiece material and a computerized machine toolprogrammer operative, prior to commencing machining of the workpiece, togenerate a machine tool program enabling a machine tool to machine theworkpiece using one of the at least one given type of milling machine,one of the at least one given type of cutting tool and one of the atleast one given type of workpiece material at at least one depth of cutand rpm, which, based on the historical mapping, avoid undesirablechatter.

Preferably, the computerized machine tool programmer includes a suitabledepth of cut and rpm ascertainer, employing known pairings of depth ofcut and rpm, which are known from the historical mapping for the giventype of milling machine, the given type of cutting tool and the giventype of workpiece material to not create UDC for the at least one giventype of milling machine, the at least one given type of cutting tool andthe at least one given type of workpiece material, in order to ascertaina suitable rpm for a given depth of cut which will not create UDC.

In accordance with a preferred embodiment of the present invention thecomputerized machine tool programmer includes a suitable depth of cutand rpm ascertainer, employing pairings of depth of cut and rpm, whichare known from the historical mapping for the given type of millingmachine, the given type of cutting tool and the given type of workpiecematerial to be within a predetermined neighborhood of known pairingsknown not to create UDC and not to be within a predeterminedneighborhood of known pairings known to create UDC for the at least onegiven type of milling machine, the at least one given type of cuttingtool and the at least one given type of workpiece material, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.

In accordance with a preferred embodiment of the present invention thecomputerized machine tool programmer includes a suitable depth of cutand rpm ascertainer, employing known pairings of depth of cut and rpm,which are known from the historical mapping for the given type ofmilling machine, the given type of cutting tool and the given type ofworkpiece material to create UDC and known pairings of depth of cut andrpm, which are known from the historical mapping for the given type ofmilling machine, the given type of cutting tool and the given type ofworkpiece material not to create UDC, in order to ascertain a suitablerpm for a given depth of cut which will not create UDC.

Preferably, the suitable rpm for the given depth of cut need notcorrespond to one of the known pairings.

In accordance with a preferred embodiment of the present invention thesuitable rpm for the given depth of cut does not correspond to one ofthe known pairings.

In accordance with a preferred embodiment of the present invention thecomputerized machine tool programmer includes an initial CNC programgenerator, initially generating an initial CNC program for machining theworkpiece without necessarily considering UDC issues, the initial CNCprogram including at least one proposed pairing of depth of cut and rpmfor at least one given type of milling machine, at least one given typeof cutting tool and at least one given type of workpiece material and aproposed pairing validator, validating the at least one proposedpairing, based on the historical mapping.

In accordance with a preferred embodiment of the present invention thecomputerized machine tool programmer includes an initial CNC programgenerator, initially generating an initial CNC program for machining theworkpiece without necessarily considering UDC issues, the initial CNCprogram including at least one proposed pairing of depth of cut and rpmfor at least one given type of milling machine, at least one given typeof cutting tool and at least one given type of workpiece material, aproposed pairing disallower, disallowing at least one of the at leastone proposed pairing, based on the historical mapping, a revised CNCprogram generator, generating at least one revised CNC program formachining the workpiece based on the historical mapping, the initial CNCprogram including at least one alternative proposed pairing of depth ofcut and rpm for at least one given type of milling machine, at least onegiven type of cutting tool and at least one given type of workpiecematerial and a revised proposed pairing validator, validating the atleast one revised proposed pairing, based on the historical mapping.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood and appreciated more fully fromthe following detailed description, taken in conjunction with thedrawings in which:

FIG. 1A is a simplified illustration of a milling CNC program generationCAM and CNC milling system and methodology including a millinghistory-based undesirable chatter avoidance module, constructed andoperative in accordance with one embodiment of the present invention,resident on a CNC program generation CAM server;

FIG. 1B is a simplified illustration of a 2.5-dimensional milling CNCprogram generation CAM and CNC milling system and methodology includinga milling history-based undesirable chatter avoidance module,constructed and operative in accordance with one embodiment of thepresent invention, resident on a CNC controller;

FIG. 1C is a simplified illustration of a 3-dimensional milling CNCprogram generation CAM and CNC milling system and methodology includinga milling history-based undesirable chatter avoidance module,constructed and operative in accordance with one embodiment of thepresent invention, resident on a CNC program generation CAM server;

FIG. 2A is a simplified illustration of a milling CNC program generationCAM and CNC milling system and methodology employing multiple machinetools and including at least one milling history-based undesirablechatter avoidance module, constructed and operative in accordance withanother embodiment of the present invention, resident on at least oneCNC program generation CAM server;

FIG. 2B is a simplified illustration of a 2.5-dimensional milling CNCprogram generation CAM and CNC milling system and methodology employingmultiple machine tools and including at least one milling history-basedundesirable chatter avoidance module, constructed and operative inaccordance with another embodiment of the present invention, resident onat least one CNC program generation CAM server;

FIG. 2C is a simplified illustration of a 3-dimensional milling CNCprogram generation CAM and CNC milling system and methodology employingmultiple machine tools and including at least one milling history-basedundesirable chatter avoidance module, constructed and operative inaccordance with one embodiment of the present invention, resident on atleast one CNC program generation CAM server;

FIG. 3A is a simplified illustration of a milling CNC program generationCAM and CNC milling system and methodology employing a multiplicity ofmachine tools, typically of various different types, and preferablyincluding a plurality of milling history-based undesirable chatteravoidance modules, at least one of which is resident on at least one CNCprogram generation CAM server, constructed and operative in accordancewith yet another embodiment of the present invention;

FIG. 3B is a simplified illustration of a milling CNC program generationCAM and CNC milling system and methodology employing a multiplicity ofmachine tools, typically of various different types, and including aplurality of milling history-based undesirable chatter avoidancemodules, at least one of which is resident on at least one a CNC programgeneration CAM server, constructed and operative in accordance with yetanother embodiment of the present invention;

FIG. 3C is a simplified illustration of a 3-dimensional milling CNCprogram generation CAM and CNC milling system and methodology employinga multiplicity of machine tools, typically of various different types,and including a plurality of milling history-based undesirable chatteravoidance modules, at least one of which is resident on at least one CNCprogram generation CAM server, constructed and operative in accordancewith yet another embodiment of the present invention; and

FIG. 4 is a simplified illustration of the development of a historicalundesirable chatter presence/absence (HUPA) map for a given workpiecematerial and tool type.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference is now made to FIG. 1A, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system 100 andmethodology including a milling history-based undesirable chatteravoidance (MHBUCA) module 110, constructed and operative in accordancewith one embodiment of the present invention, preferably resident on aCNC program generation CAM (CNCPGCAM) server 120. The CNCPGCAM server120 provides a CNC program which is supplied to a CNC controller 122 ofone or more CNC milling machines, such as a CNC machining center 124.The CNC program includes, inter alia, a tool path, spindle on/offcommands, tool change commands, rpm commands, feed commands and coolanton/off commands.

The CNCPGCAM server 120 may be any suitable CNC program generation CAMserver and is preferably a server hosting milling CNC program generation(MCNCPG) software 130. The MCNCPG software 130 preferably includes toolpath generation (TPG) software 132 and cutting conditions management(CCM) software 134.

A preferred type of MCNCPG software 130 is Solidcam™ milling CNC programgeneration software and includes cutting conditions management software134 embodied in an IMACHINING® module, which provides an outputincluding a set of cutting conditions suitable for each point along agiven toolpath. Solidcam™ milling CNC program generation software iscommercially available from the assignee of the present application,SolidCAM Ltd. of Or-Yehuda, Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 1A is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present invention,MHBUCA module 110 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides undesirable chatter (UDC) avoidance as part of the CNC programgeneration.

In the embodiment of FIG. 1A, the MCNCPG software 130 in CNCPGCAM server120 is located in an engineering room wherein production engineersinteract with the CNCPGCAM server 120 to generate the CNC programs whichare downloaded to the CNC controller 122 of each CNC machining center124.

The MHBUCA module 110 employs empirical data obtained from machiningactivity on at least one workpiece material at an earlier time, whichdata is stored in a historical empirical data (HED) database 136,associated therewith, to generate and store historical mappingsindicating which pairings of depth of cut and rpm produce or do notproduce tool undesirable chatter when at least one given type of tool isused to machine at least one given type of workpiece material. It is aparticular feature of an embodiment of the present invention that theMHBUCA module 110 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, inproviding chatter avoidance.

In the illustrated embodiment of FIG. 1A, the historical empirical datais derived from earlier operation of a CNC machining center 124 and isemployed to generate subsequent undesirable chatter-free (UDC-free) CNCprograms for CNC machining center 124, such that milling operation ofthe CNC machining center 124 based on the CNC programs thus generatedavoids undesirable chatter (UDC).

For the purposes of the present application “chatter” is defined asself-reinforced vibration of a cutting tool by its interaction with aworkpiece surface being cut. “Undesirable Chatter” or UDC is defined aschatter having an amplitude above an acceptable threshold level,exceedance of which may damage one or more of cutting edges, an insert,an insert holder, a machine tool and the workpiece. In practice, theamplitude threshold is decided by a human, normally an experiencedmilling machine operator. Different amplitude thresholds may apply,inter alia, to different workpiece materials, different tools, differentmachine tools and different workpieces.

The following academic articles and patent publications which relate tochatter are hereby incorporated by reference:

-   Chong Peng, et al., Time-Domain Simulation and Experimental    Verification of Dynamic Cutting Forces and Chatter Stability for    Circular Corner Milling, Proceedings of the Institution of    Mechanical Engineers, Part B: Journal of Engineering Manufacture,    volume 229, no. 6, pages 932-939, June 2015, published online before    print Jun. 18, 2014;-   Jifang Tian, et al, Chatter Instability in Milling Systems with    Flexible Rotating Spindles—A New Theoretical Approach, Journal of    Manufacturing Science and Engineering, volume 123, issue 1, pages    1-9, Jul. 1, 1999;-   Pavel Bach, et al, A Comparative Analysis of Lower Speed Chatter    Behavior, MM Science Journal, December 2013, page 434-440;-   U.S. Published Patent Application 2014/0114462A1 Yoshino et al,    published Apr. 24, 2014; and-   U.S. Pat. No. 8,862,429, dated Oct. 14, 2014.

In accordance with a preferred embodiment of the invention, one or moremicrophone 160 is mounted on CNC machining center 124, such as withinthe machining chamber 162 of the CNC machining center 124 or on an outerhousing thereof. The CNC machining center 124 also typically includesCNC controller 122. An output of microphone 160 is supplied tomicrophone input circuitry 170, forming part of MHBUCA module 110, andwhich may include spectral analysis functionality 172, such as FastFourier Transformation (FFT) functionality, which transforms themicrophone output, which is in the time domain, to the frequency domain.

An output of the microphone input circuitry 170, which preferablyincludes the spectral analysis functionality 172, is in the frequencydomain and is supplied to a UDC identifier 180, which identifies peaksin the frequency domain, which are not coincident with any of theharmonic peaks characteristic of the tooth passing frequency. If suchpeaks exceed a given height, corresponding to a predetermined amplitudethreshold characterizing UDC, the presence of UDC is identified.

A historical map generator 190 receives a UDC presence input from theUDC identifier 180 having a time stamp and also receives, from CNCcontroller 122, at least one input providing current informationindicating the tool currently being used in milling, the workpiecematerial being milled, the current depth of cut and the current rpm. Onthe basis of the aforesaid inputs, the historical map generator 190creates a plurality of historical UDC presence/absence (HUPA) maps 200.It is a particular feature of an embodiment of the present inventionthat the HUPA maps 200 include depth of cut and rpm pairs for most orall instances where UDC did not occur. Preferably, but not necessarily,the HUPA maps 200 also include depth of cut and rpm pairs for most orall instances where UDC did occur.

For the purposes of the present application, each HUPA map 200 isspecific to a given combination of workpiece material, type of tool andmachine tool, here designated WMTTMT.

It is appreciated that separate HUPA maps 200 may be generated for agiven WMTTMT based on various additional parameters including, forexample a level of tool wear or the applicable threshold used fordefining UDC. It is further appreciated that even more specific HUPAmaps 200 may be generated for a given WMTTMT for each combination of aplurality of selectable machining parameters, for example, the cornerradius of each cutting edge, the rake angle of each cutting edge, theflute helix angle of each cutting edge, the number of layers of insertsin an insert cutter, the number of inserts in each layer, the dimensionsof each insert and the extent of overlap between layers of inserts.

The type of tool may be broken down, for example, as follows:

-   -   Solid carbide end mill        -   Overall Cutting Diameter        -   Cutting length and/or depth        -   Shank diameter        -   Type of carbide powder employed        -   Number of flutes        -   Helix angle/angles of flutes        -   Rake angle of cutting edge        -   Clearance angle of cutting edge        -   Fixed/Variable Angular spacing between flutes        -   Diameter of central core        -   Configuration of bottom, for example            -   Straight bottom            -   Ball nose bottom            -   Bull nose bottom    -   Insert cutters        -   Insert Type            -   Type of carbide powder employed            -   Cutting length and/or depth            -   Rake angle of cutting edge            -   Clearance angle of cutting edge            -   Corner radius        -   Holder shank diameter        -   Number of flutes        -   Helix angle/angles of flutes        -   Fixed/Variable Angular spacing between flutes        -   Diameter of central core        -   Configuration of bottom, for example            -   Straight bottom            -   Ball nose bottom

It is appreciated that preferably, HUPA maps 200 are built up based onactual recorded microphone inputs from actual past machining operationson multiple workpieces. Thus, as seen in FIG. 4 , initially only a fewpixels, representing specific depth of cut and rpm pairings, appear,here typically represented by a black solid pixel indicating the absenceof UDC and preferably also by a cross-hatched pixel indicating thepresence of UDC. These pairings represent actual depth of cut and rpmpairings of historical machining operations for a given type of tool andmaterial using the CNC machining center 124.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining of the CNC machining center 124, more andmore pixels in each map are filled in, typically by a black solid pixelindicating the absence of UDC or by a cross-hatched pixel indicating thepresence of UDC. A simplified illustration of the progressive buildingof the historical maps is seen in FIG. 4 , which presents a mapprogression. It is appreciated that each different WMTTMT may preferablyhave its own map progression. FIG. 4 shows the map as it is built upover time, at three different times, typically separated one from theother by 3 months. It is seen that over time the pixels of the map aretypically increasingly filled in with black solid pixels and arepreferably also filled in with cross-hatched pixels. It is also seenthat over time the black solid pixels tend to be increasingly groupedtogether, to the exclusion of cross-hatched pixels, thus indicatingranges of pairs of depth of cut and rpm for which UDC did nothistorically occur. This grouping also typically occurs for thecross-hatched pixels, indicating the presence of UDC.

The latest HUPA map 200 for each different WMTTMT is preferably storedin historical empirical data (HED) database 136 and is automaticallyconsulted by the MCNCPG software 130, such as the IMACHINING® software,to validate the acceptability of the CNC program generated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 130 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 130 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 130 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 130 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 130 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 130 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 130 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 130 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 130        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 130 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 130 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        130 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 130 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 130; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 130.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software130 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 130, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software130 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 130, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 130.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 134 is provided, the TPG software132 provides a proposed tool path output, defining for each machiningoperation: particulars of the tool, the depth of cut, the nominal feedspeed and the tool trajectory, to the CCM software 134. The CCM software134 provides, on the basis of the proposed tool path output, a cuttingconditions output, defining for each machining operation: toolengagement angles for each point along the trajectory, the feed speed ateach point along the trajectory and the rpm. The CCM software 134 and/orthe TPG software 132 provide an undesirable chatter (UDC) avoidanceinput to MHBUCA module 110 including for each machining operation: theWMTTMT, the depth of cut, and the rpm.

MHBUCA module 110 consults HED database 136, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT or are validated as described hereinabove, nochange in the rpm is made by MHBUCA module 110.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 110, basedon HED database 136, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTTMT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 110, theproposed replacement rpm is output to the CCM software 134, whichconfirms that the replacement rpm is suitable for use for the givenWMTTMT under the cutting conditions already established by the CCMsoftware 134 for the given operation. This confirmation is provided bythe CCM software 134 to the MCNCPG software 130, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller122, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 134 is not provided, the MCNCPG software 130provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTTMT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 110.

MHBUCA module 110 consults HED database 136, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT or are validated as described above, no change inthe rpm is made by MHBUCA module 110.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 110, basedon HED database 136, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTTMT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 110, theproposed replacement rpm is output to the MCNCPG software 130, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 130 provides a final UDC-free CNC program ready for loadingonto the CNC controller 122 prior to commencement of machining.

It is appreciated that in accordance with a preferred embodiment of thepresent invention, the system operates initially in a learning modewherein most of the pixels in the HUPA maps 200, each representing adepth of cut and rpm pairing for a given machine, tool and workpiecematerial, are not yet marked as UDC or UDC-free pixels. In such cases,there are expected to be many situations in which a proposed pair isneither validated nor disallowed and where the system carries outmachining without a definite prediction regarding UDC. It will beappreciated by persons skilled in the art that the likelihood that thesystem will be able to accurately predict whether or not a givennon-marked pixel will be UDC-free depends on the density of markedpixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 130 provides a final CNC program usingthe proposed depth of cut/rpm pair, ready for loading onto the CNCcontroller 122 prior to commencement of machining.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software130 in CNCPGCAM server 120, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 200, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 200 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 200 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 200, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 1B, which is a simplified illustration ofa 2.5D milling CNC program generation CAM and CNC milling system 300 andmethodology including a milling history-based undesirable chatter (UDC)avoidance (MHBUCA) module 310, constructed and operative in accordancewith another embodiment of the present invention. In this embodiment ofthe present invention, a CNC program generation CAM (CNCPGCAM) server320 is preferably resident on a CNC controller 322, and provides a 2.5DCNC program, which is employed by the CNC controller 322 to operate aCNC milling machine, such as a CNC machining center 324. The CNC programincludes inter alia, a tool path, spindle on/off commands, tool changecommands, rpm commands, feed commands and coolant on/off commands.

The CNC program generation CAM server 320 may be any suitable 2.5D CNCprogram generation CAM server and is preferably a server hosting 2.5Dmilling CNC program generation (MCNCPG) software 330. The MCNCPGsoftware 330 preferably includes tool path generation (TPG) software 332and cutting conditions management (CCM) software 334.

A preferred type of milling CNC program generation (MCNCPG) software 330is Solidcam™ milling CNC program generation software and includescutting conditions management (CCM) software 334 embodied in anIMACHINING® 2.5D module, which provides an output including a set ofcutting conditions suitable for each point along a given toolpath.Solidcam™ milling CNC program generation software is commerciallyavailable from the assignee of the present application, SolidCAM Ltd. ofOr-Yehuda, Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 1B is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present inventionMHBUCA module 310 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides undesirable chatter (UDC) avoidance as part of the CNC programgeneration.

In the embodiment of FIG. 1B, the MCNCPG software 330 in CNCPGCAM server320 is located in CNC controller 322.

The MHBUCA module 310 employs empirical data obtained from machiningactivity on at least one workpiece material at an earlier time, whichdata is stored in a historical empirical data (HED) database 336,associated therewith, to generate and store historical mappingsindicating which pairings of depth of cut and rpm produce or do notproduce UDC when at least one given type of tool is used to machine atleast one given type of workpiece material. It is a particular featureof an embodiment of the present invention that the MHBUCA module 310stores and utilizes pairs of depth of cut and rpm at which UDC did notoccur for past machining, using at least one given type of millingmachine, at least one given type of cutting tool and at least one giventype of workpiece material, in providing chatter avoidance.

In the illustrated embodiment of FIG. 1B, the historical empirical datais derived from earlier operation of CNC machining center 324 and isemployed to generate subsequent UDC-free CNC programs for CNC machiningcenter 324, such that milling operation of the CNC machining center 324based on the CNC programs thus generated avoids UDC.

As in the embodiment of FIG. 1A, at least one microphone 340 ispreferably mounted on CNC machining center 324, such as within themachining chamber 341 of the CNC machining center 324 or on an outerhousing thereof. An output of microphone 340 is supplied to microphoneinput circuitry 342, forming part of MHBUCA module 310, which preferablyincludes spectral analysis functionality 344, which preferably operatesas described hereinabove. MHBUCA module 310 preferably also includes aUDC identifier 346 which outputs to a historical map generator 348,which, as described hereinabove, creates a plurality of historical UDCpresence/absence (HUPA) maps 350, as described hereinabove. It is aparticular feature of an embodiment of the present invention that theHUPA maps 350 include depth of cut and rpm pairs for most or allinstances where UDC did not occur. Preferably, but not necessarily, theHUPA maps 350 also include depth of cut and rpm pairs for most or allinstances where UDC did occur.

The latest HUPA map 350 for each different WMTTMT is preferably storedin HED database 336 and is automatically consulted by the MCNCPGsoftware 330, such as the IMACHINING® software, to validate theacceptability of the CNC program generated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 330 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 330 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 330 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 330 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 330 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 330 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 330 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 330 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 330        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 330 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 330 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        330 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 330 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 330; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 330.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software330 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 330, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software330 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 330, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 330.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein cutting conditions management (CCM) software334 is provided, the TPG software 332 provides a proposed tool pathoutput, defining for each machining operation: particulars of the tool,the depth of cut, the nominal feed speed and the tool trajectory to theCCM software 334. The CCM software 334 provides, on the basis of theproposed tool path output, a cutting conditions output, defining foreach machining operation: tool engagement angles for each point alongthe trajectory, the feed speed at each point along the trajectory andthe rpm. The CCM software 334 and/or the TPG software 332 provide anundesirable chatter (UDC) avoidance input to MHBUCA module 310 includingfor each machining operation: the WMTTMT, the depth of cut, and the rpm.

MHBUCA module 310 consults HED database 336, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, no change in the rpm is made by MHBUCA module 310.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 310, basedon HED database 336, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT and preferably also indicating which pairings of depthof cut and rpm did historically produce UDC for the given WMTTMT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 310, theproposed replacement rpm is output to the CCM software 334, whichconfirms that the replacement rpm is suitable for use for the givenWMTTMT under the cutting conditions already established by the CCMsoftware 334 for the given operation. This confirmation is provided bythe CCM software 334 to the MCNCPG software 330 which provides a final,UDC-free CNC program output ready for execution by the CNC controller322 prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 334 is not provided, the MCNCPG software 330provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTTMT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 310.

MHBUCA module 310 consults HED database 336, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described above, no change inthe rpm is made by MHBUCA module 310.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 310, basedon HED database 336, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTTMT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 310, theproposed replacement rpm is output to the MCNCPG software 330, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 330 provides a final UDC-free CNC program ready for executionby the CNC controller 322, prior to commencement of machining.

As noted above with reference to the embodiment of FIG. 1A, thispreferred embodiment of the present invention operates initially in alearning mode wherein most of the pixels in the HUPA maps 350, eachrepresenting a depth of cut and rpm pairing for a given machine, tooland workpiece material, are not yet marked as UDC or UDC-free pixels. Insuch cases, there are expected to be many situations in which a proposedpair is neither validated nor disallowed and where the system carriesout machining without a definite prediction regarding UDC. It will beappreciated by persons skilled in the art that the likelihood that thesystem will be able to accurately predict whether or not a givennon-marked pixel will be UDC-free depends on the density of markedpixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 330 provides a final CNC program usingthe proposed depth of cut/rpm pair, ready for loading onto the CNCcontroller 322 prior to commencement of machining.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software330 in CNCPGCAM server 320, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 350, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 350 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 350 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 350, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 1C, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system 400 andmethodology including a milling history-based undesirable chatter (UDC)avoidance (MHBUCA) module 410, constructed and operative in accordancewith another embodiment of the present invention. The embodiment of FIG.1C is preferably a 3D system although alternatively it may be a 2.5Dsystem. A CNC program generation CAM (CNCPGCAM) server 420 is preferablyresident on the cloud and provides a CNC program, which is employed by aCNC controller 422 to operate a CNC milling machine such as a CNCmachining center 424. The CNC program includes inter alia, a tool path,spindle on/off commands, tool change commands, rpm commands, feedcommands and coolant on/off commands. An operator may control operationof system 400 locally or remotely via a wireless device 426, such as anI-PAD.

The CNC program generation CAM server 420 may be any suitable CNCprogram generation CAM server and is preferably a server hosting millingCNC program generation (MCNCPG) software 430. The MCNCPG software 430preferably includes tool path generation (TPG) software 432 and cuttingconditions management (CCM) software 434.

A preferred type of milling CNC program generation (MCNCPG) software 430is Solidcam™ milling CNC program generation software and includescutting conditions management (CCM) software 434 embodied in anIMACHINING® module, which provides an output including a set of cuttingconditions suitable for each point along a given toolpath. Solidcam™milling CNC program generation software is commercially available fromthe assignee of the present application, SolidCAM Ltd. of Or-Yehuda,Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 1C is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present inventionMHBUCA module 410 is preferably resident on the cloud and stores andutilizes pairs of depth of cut and rpm at which undesirable chatter(UDC) did not occur for past machining, using at least one given type ofmilling machine, at least one given type of cutting tool and at leastone given type of workpiece material, and thus provides undesirablechatter (UDC) avoidance as part of the CNC program generation.

The MHBUCA module 410 employs empirical data obtained from machiningactivity on at least one workpiece material at an earlier time, whichdata is stored in a historical empirical data (HED) database 436,associated therewith, to generate and store historical mappingsindicating which pairings of depth of cut and rpm produce or do notproduce UDC when at least one given type of tool is used to machine atleast one given type of workpiece material. It is a particular featureof an embodiment of the present invention that the MHBUCA module 410stores and utilizes pairs of depth of cut and rpm at which UDC did notoccur for past machining, using at least one given type of millingmachine, at least one given type of cutting tool and at least one giventype of workpiece material, in providing chatter avoidance. HED database436 is preferably also located on the cloud, but may alternatively belocated at the CNC controller 422 or elsewhere.

In the illustrated embodiment of FIG. 1C, the historical empirical datais derived from earlier operation of CNC machining center 424 and isemployed to generate subsequent UDC-free CNC programs for CNC machiningcenter 424, such that subsequent milling operation of the CNC machiningcenter 424 based on the CNC programs thus generated avoids UDC.

As in the embodiments of FIGS. 1A and 1B, at least one microphone 440 ispreferably mounted on CNC machining center 424 and its output issupplied to microphone input circuitry 442, which preferably includesspectral analysis functionality 444. Microphone input circuitry 442forms part of MHBUCA module 410, which preferably operates as describedhereinabove, and also includes a UDC identifier 446 which outputs to ahistorical map generator 448, which, as described hereinabove, creates aplurality of historical UDC presence/absence (HUPA) maps 450, asdescribed hereinabove. It is a particular feature of an embodiment ofthe present invention that the HUPA maps 450 include depth of cut andrpm pairs for most or all instances where UDC did not occur. Preferably,but not necessarily, the HUPA maps 450 also include depth of cut and rpmpairs for most or all instances where UDC did occur.

The latest HUPA map 450 for each different WMTTMT is preferably storedin a database 460, which may be identical with or separate from HEDdatabase 436, and is automatically consulted by the tool generationsoftware, such as the IMACHINING® software, to validate theacceptability of the CNC program generated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 430 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 430 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 430 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 430 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 430 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 430 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 430 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 430 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 430        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 430 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 430 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        430 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 430 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 430; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 430.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software430 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 430, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software430 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 430, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 430.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 434 is provided, the TPG software432 provides a proposed tool path output, defining for each machiningoperation: particulars of the tool, the depth of cut, the nominal feedspeed and the tool trajectory, to the CCM software 434. The CCM software434 provides, on the basis of the proposed tool path output, a cuttingconditions output, defining for each machining operation: toolengagement angles for each point along the trajectory, the feed speed ateach point along the trajectory and the rpm. The CCM software 434 and/orthe TPG software 432 provide a UDC avoidance input to MHBUCA module 410including for each machining operation: the WMTTMT, the depth of cut,and the rpm.

MHBUCA module 410 consults HED database 436, associated therewith, ordatabase 460, which may be associated with CNC controller 422, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described hereinabove, nochange in the rpm is made by MHBUCA module 410.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described hereinabove, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 410, basedon the historical mappings indicating which pairings of depth of cut andrpm did not historically produce UDC for the given WMTTMT and preferablyalso indicating which pairings of depth of cut and rpm did historicallyproduce UDC for the given WMTTMT. Preferably, an rpm which is higherthan the UDC-problematic rpm is selected, however, there may beinstances where an rpm which is lower than the UDC-problematic rpm isselected.

Where a change in the rpm is proposed by the MHBUCA module 410, theproposed replacement rpm is output to the CCM software 434, whichconfirms that the replacement rpm is suitable for use for the givenWMTTMT under the cutting conditions already established by the CCMsoftware 434 for the given operation. This confirmation is provided bythe CCM software 434 to the MCNCPG software 430 which provides a final,UDC-free CNC program output ready for execution by the CNC controller422, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 434 is not provided, the MCNCPG software 430provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTTMT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 410.

MHBUCA module 410 consults HED database 436, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described above, no change inthe rpm is made by MHBUCA module 410.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 410, basedon the historical mappings indicating which pairings of depth of cut andrpm did not historically produce UDC for the given WMTTMT and preferablyalso indicating which pairings of depth of cut and rpm did historicallyproduce UDC for the given WMTTMT. Preferably, an rpm which is higherthan the UDC-problematic rpm is selected, however, there may beinstances where an rpm which is lower than the UDC-problematic rpm isselected.

Where a change in the rpm is proposed by the MHBUCA module 410, theproposed replacement rpm is output to the MCNCPG software 430, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 430 provides a final UDC-free CNC program ready for executionby the CNC controller 422 prior to commencement of machining.

As noted above with reference to the embodiments of FIGS. 1A and 1B,this preferred embodiment of the present invention operates initially ina learning mode wherein most of the pixels in the HUPA maps 450, eachrepresenting a depth of cut and rpm pairing for a given machine, tooland workpiece material, are not yet marked as UDC or UDC-free pixels. Insuch cases, there are expected to be many situations in which a proposedpair is neither validated nor disallowed and where the system carriesout machining without a definite prediction regarding UDC. It will beappreciated by persons skilled in the art that the likelihood that thesystem will be able to accurately predict whether or not a givennon-marked pixel will be UDC-free depends on the density of markedpixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, the MCNCPG software 430 provides a final CNC program using theproposed depth of cut/rpm pair, ready for loading onto the CNCcontroller 422 prior to commencement of machining.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software430 in CNCPGCAM server 420, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 450, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 450 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 450 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 450, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 2A, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system 500 andmethodology employing multiple machine tools, typically of differenttypes made by different manufacturers and here designated by referencenumerals 502, 504, 506 and 508. The multiple machine tools may or maynot be in a common physical location.

System 500 preferably comprises at least one milling history-basedundesirable chatter (UDC) avoidance (MHBUCA) module 510, constructed andoperative in accordance with one embodiment of the present invention,preferably resident on at least one CNC program generation CAM(CNCPGCAM) server 520. The CNCPGCAM server 520 provides a CNC programwhich is supplied to at least one CNC controller 522 of one or more CNCmilling machines, such as CNC milling machining centers 524. The CNCprogram preferably includes, inter alia, a tool path, spindle on/offcommands, tool change commands, rpm commands, feed commands and coolanton/off commands.

The CNCPGCAM server 520 may be any suitable CNC program generation CAMserver and is preferably a server hosting milling CNC program generation(MCNCPG) software 530. The MCNCPG software 530 preferably includes toolpath generation (TPG) software 532 and cutting conditions management(CCM) software 534.

A preferred type of MCNCPG software 530 is Solidcam™ milling CNC programgeneration software and includes cutting conditions management software534 embodied in an IMACHINING® module, which provides an outputincluding a set of cutting conditions suitable for each point along agiven toolpath. Solidcam™ milling CNC program generation software iscommercially available from the assignee of the present application,SolidCAM Ltd. of Or-Yehuda, Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 2A is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present invention,MHBUCA module 510 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides undesirable chatter (UDC) avoidance as part of the CNC programgeneration.

In the embodiment of FIG. 2A, the MCNCPG software 530 in CNCPGCAM server520 is located in an engineering room wherein production engineersinteract with the CNCPGCAM server 520 to generate the CNC programs whichare downloaded to CNC controllers 522 of each one of multiple CNCmachining centers 524.

The MHBUCA module 510 employs empirical data obtained from machiningactivity on at least one workpiece material at an earlier time, whichdata is stored in a historical empirical data (HED) database 536,associated therewith, to generate and store historical mappingsindicating which pairings of depth of cut and rpm produce or do notproduce tool undesirable chatter (UDC) when at least one given type oftool is used to machine at least one given type of workpiece material.It is a particular feature of an embodiment of the present inventionthat the MHBUCA module 510 stores and utilizes pairs of depth of cut andrpm at which UDC did not occur for past machining, using at least onegiven type of milling machine, at least one given type of cutting tooland at least one given type of workpiece material, in providing chatteravoidance.

In the illustrated embodiment of FIG. 2A, the historical empirical datais derived from earlier operation of one or more CNC machining center524 and is employed to generate subsequent UDC-free CNC programs for oneor more CNC machining center 524, such that milling operation of the CNCmachining centers 524 based on the CNC programs thus generated avoidsUDC.

In accordance with a preferred embodiment of the invention, one or moremicrophone 560 is mounted on each CNC machining center 524, such aswithin the machining chamber 562 of the CNC machining center 524 or onan outer housing thereof. Each CNC machining center 524 also typicallyincludes CNC controller 522. An output of microphone 560 is supplied tomicrophone input circuitry 570, forming part of MHBUCA module 510, andwhich may include spectral analysis functionality 572, such as FastFourier Transformation (FFT) functionality, which transforms themicrophone output, which is in the time domain, to the frequency domain.

An output of the microphone input circuitry 570, which preferablyincludes the spectral analysis functionality 572, is in the frequencydomain and is supplied to a UDC identifier 580 which identifies peaks inthe frequency domain, which are not coincident with any of the harmonicpeaks characteristic of the tooth passing frequency. If such peaksexceed a given height, corresponding to a predetermined amplitudethreshold characterizing UDC, the presence of UDC is identified.

A historical map generator 590 receives a UDC presence input from theUDC identifier 580 having a time stamp and also receives, from the CNCcontroller 522 of the corresponding CNC machining center 524, at leastone input providing current information indicating the tool currentlybeing used in milling, the workpiece material being milled, the currentdepth of cut and the current rpm. On the basis of the aforesaid inputs,the historical map generator 590 creates a plurality of historical UDCpresence/absence (HUPA) maps 600. It is a particular feature of anembodiment of the present invention that the HUPA maps 600 include depthof cut and rpm pairs for most or all instances where UDC did not occur.Preferably, but not necessarily, the HUPA maps 600 also include depth ofcut and rpm pairs for most or all instances where UDC did occur.

Historical map generator 590 may receive a UDC presence input from atleast one UDC identifier 580 based on empirical data originating frommachines of the same type, manufactured by a same manufacturer oralternatively based on empirical data from machines of different types,manufactured by a same manufacturer. As a further alternative,historical map generator 590 may receive a UDC presence input from atleast one UDC identifier 580 based on empirical data from machines ofdifferent types, manufactured by different manufacturers.

For the purposes of the present application, each HUPA map 600 isspecific to a given combination of workpiece material and type of tool,here designated WMTT.

In accordance with one embodiment of the invention, similarly to thecase described above with reference to FIGS. 1A-1C, each HUPA map 600 ismachine tool specific as well and thus HUPA maps 600 are generated foreach of the multiple machine tools in a shop. This is particularlyrelevant when the various CNC machining centers 524 are of differenttypes or have different overall operating characteristics, which renderthem suitable for different machining tasks. In such a case, thegeneration of machine tool specific HUPA maps 600 is useful in enablingproduction planning and allocation of machining resources.

In accordance with another embodiment of the invention, as distinguishedfrom the case described above with reference to FIGS. 1A-1C, non-machinetool specific HUPA (NMTSHUPA) maps 600 may be generated based onempirical data received from multiple machine tools having at least apredetermined level of similarity. For example, the multiple machinetools whose empirical data is used for generating a NMTSHUPA map 600 maybe manufactured by different manufacturers but have the same power andspeed capabilities. In another example, the multiple machine tools whoseempirical data is used for generating a NMTSHUPA map 600 may bemanufactured by the same manufacturer and have similar mechanicalstructures but have different spindle ratings. In a further example, themultiple machine tools whose empirical data is used for generating aNMTSHUPA map 600 may be manufactured by the same manufacturer ordifferent manufacturers and have similar mechanical structures,rigidity, and ranges of movements along their various axes.

It is appreciated that separate NMTSHUPA maps 600 may be generated for agiven WMTT based on various additional parameters including, forexample, a level of tool wear or a different threshold applicable to thedefinition of UDC. It is further appreciated that even more specificNMTSHUPA maps 600 may be generated for a given WMTT for each combinationof a plurality of selectable machining parameters, for example, thecorner radius of each cutting edge, the rake angle of each cutting edge,the flute helix angle of each cutting edge, the number of layers ofinserts in an insert cutter, the number of inserts in each layer, thedimensions of each insert and the extent of overlap between layers ofinserts.

It is appreciated that preferably, NMTSHUPA maps 600 are built up basedon actual recorded microphone inputs from actual past machiningoperations on multiple workpieces. Thus, similarly to that describedhereinabove with reference to FIG. 4 , initially only a few pixels,representing specific depth of cut and rpm pairings, appear, heretypically represented by a black solid pixel indicating the absence ofUDC and preferably also by a cross-hatched pixel indicating the presenceof UDC. These pairings represent actual depth of cut and rpm pairings ofhistorical machining operations for a given type of tool and materialusing one or more CNC machining centers 524.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining carried out by CNC machining centers 524,more and more pixels in each HUPA map 600 are filled in, typically by ablack solid pixel indicating the absence of UDC or by a cross-hatchedpixel indicating the presence of UDC. The latest HUPA map 600 for eachdifferent WMTT is preferably stored in HED database 536 and isautomatically consulted by the MCNCPG software 530, such as theIMACHINING® software, to validate the acceptability of the CNC programgenerated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 530 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 530 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 530 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 530 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 530 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 530 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 530 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 530 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 530        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 530 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 530 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        530 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 530 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

-   -   1. Proceed to machine the workpiece using the depth of cut/rpm        pair proposed by the MCNCPG software 530; or    -   2. Perform further analysis of the depth of cut/rpm pair        proposed by the MCNCPG software 530.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software530 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 530, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software530 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 530, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 530.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein cutting conditions management (CCM) software534 is provided, the TPG software 532 provides a proposed tool pathoutput, defining for each machining operation: particulars of the tool,the depth of cut, the nominal feed speed and the tool trajectory, to theCCM software 534. The CCM software 534 provides, on the basis of theproposed tool path output, a cutting conditions output, defining foreach machining operation: tool engagement angles for each point alongthe trajectory, the feed speed at each point along the trajectory andthe rpm. The CCM software 534 and/or the TPG software 532 provide a UDCavoidance input to MHBUCA module 510 including for each machiningoperation: the WMTT, the depth of cut, and the rpm.

MHBUCA module 510 consults HED database 536, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 510.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 510, basedon HED database 536, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 510, theproposed replacement rpm is output to the CCM software 534, whichconfirms that the replacement rpm is suitable for use for the given WMTTunder the cutting conditions already established by the CCM software 534for the given operation. This confirmation is provided by the CCMsoftware 534 to the MCNCPG software 530, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller522 of a given machine tool, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 534 is not provided, MCNCPG software 530 provides aproposed CNC program output, defining for each machining operation: theWMTT, the depth of cut, the rpm, the feed speeds and the tool trajectoryin response to a user-defined nominal cutting conditions input, definingfor each machining operation along a proposed tool trajectory: nominaltool engagement angle, nominal feed speed, depth of cut and rpm.

The particulars of the WMTT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 510.

MHBUCA module 510 consults HED database 536, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described above, no change inthe rpm is made by MHBUCA module 510.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 510, basedon HED database 536, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Additionally or alternatively, where multiple machine tools having atleast somewhat different characteristics are suitable and available fora given machining operation for a given WMTT and where HED database 536contains multiple HUPA maps 600 corresponding to different availablemachine tools, the MHBUCA module 510 may select one or more specificmachine tools from among all of the suitable and available machine toolsto carry out the machining operation. Furthermore, the MHBUCA module 510may select one or more specific machine tools from among all of thesuitable and available machine tools which will carry out the givenmachining operation in an optimal manner not only from the perspectiveof UDC avoidance but also from the perspective of machining efficiency,such as machining cycle time.

Where a change in the rpm is proposed by the MHBUCA module 510, theproposed replacement rpm is output to the MCNCPG software 530, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 530 provides a final UDC-free CNC program ready for loadingonto the CNC controller 522 prior to commencement of machining.

It is appreciated that this embodiment of the present invention operatesinitially in a learning mode wherein most of the pixels in the HUPA maps600, each representing a depth of cut and rpm pairing for a givenmachine, tool and workpiece material, are not yet marked as UDC orUDC-free pixels. In such cases, there are expected to be many situationsin which a proposed pair is neither validated nor disallowed and wherethe system carries out machining without a definite prediction regardingUDC. It will be appreciated by persons skilled in the art that thelikelihood that the system will be able to accurately predict whether ornot a given proposed non-marked pixel will be UDC-free depends on thedensity of marked pixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 530 provides a final CNC program usingthe proposed depth of cut/rpm pair, ready for loading onto the CNCcontroller 522 prior to commencement of machining.

It is a particular feature of the embodiment of the present inventiondescribed hereinabove with reference to FIG. 2A, that where the proposeddepth of cut/rpm pair is neither validated nor disallowed based onmachine tool specific HUPA maps 600, MHBUCA module 510 may consultnon-machine tool specific HUPA maps 600 in HED database 536, which,being based on a relatively large number of machining events may besubstantially more populated than corresponding machine tool specificHUPA maps 600.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software530 in CNCPGCAM server 520, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 600, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 600 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 600 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 600, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 2B, which is a simplified illustration ofa 2.5D milling CNC program generation CAM and CNC milling system 700 andmethodology including a milling history-based undesirable chatter (UDC)avoidance (MHBUCA) module 710, constructed and operative in accordancewith another embodiment of the present invention. In this embodiment ofthe present invention, a CNC program generation CAM (CNCPGCAM) server720 is preferably resident on a notebook computer 722 carried by aproduction manager.

Preferably, CNCPGCAM server 720 communicates with CNC controllers 724 ofa plurality of machine tools which are managed by the productionmanager, and provides a CNC program, which is employed by each of theCNC controllers 724 to operate a corresponding CNC milling machine, suchas a CNC machining center 725. The CNC program includes inter alia, atool path, spindle on/off commands, tool change commands, rpm commands,feed commands and coolant on/off commands.

The CNCPGCAM server 720 may be any suitable CNC program generation CAMserver and is preferably a server hosting milling CNC program generation(MCNCPG) software 730. The MCNCPG software 730 preferably includes toolpath generation (TPG) software 732 and cutting conditions management(CCM) software 734.

A preferred type of milling CNC program generation (MCNCPG) software 730is Solidcam™ milling CNC program generation software and includescutting conditions management (CCM) software 734 embodied in anIMACHINING® module, which provides an output including a set of cuttingconditions suitable for each point along a given toolpath. Solidcam™milling CNC program generation software is commercially available fromthe assignee of the present application, SolidCAM Ltd. of Or-Yehuda,Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 2B is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present inventionMHBUCA module 710 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides UDC avoidance as part of the CNC program generation. In theembodiment of FIG. 2B, the MCNCPG software 730 in CNCPGCAM server 720 islocated on the notebook computer 722.

MHBUCA module 710 employs empirical data obtained from machiningactivity on at least one workpiece material at an earlier time, whichdata is stored in a historical empirical data (HED) database 736,associated therewith, to generate and store historical mappingsindicating which pairings of depth of cut and rpm produce or do notproduce UDC when at least one given type of tool is used to machine atleast one given type of workpiece material. It is a particular featureof an embodiment of the present invention that the MHBUCA module 710stores and utilizes pairs of depth of cut and rpm at which undesirablechatter (UDC) did not occur for past machining, using at least one giventype of milling machine, at least one given type of cutting tool and atleast one given type of workpiece material, in providing chatteravoidance.

In the illustrated embodiment of FIG. 2B, the historical empirical datais derived from earlier operation of CNC machining center 725 and isemployed to generate subsequent UDC-free CNC programs for CNC machiningcenter 725, such that milling operation of the CNC machining center 725based on the CNC programs thus generated avoids UDC.

As in the embodiment of FIG. 2A, at least one microphone 740 ispreferably mounted on each CNC machining center 725 and its output issupplied to microphone input circuitry 742, which preferably includesspectral analysis functionality 744. Microphone input circuitry 742forms part of MHBUCA module 710, which preferably operates as describedhereinabove and also includes a UDC identifier 746, which outputs to ahistorical map generator 748, which, as described hereinabove, creates aplurality of historical UDC presence/absence (HUPA) maps 750, asdescribed hereinabove.

Historical map generator 748 receives a UDC presence input from the UDCidentifier 746 having a time stamp and also receives, from each CNCcontroller 724 of a plurality of corresponding CNC machining centers725, at least one input providing current information indicating thetool currently being used in milling, the workpiece material beingmilled, the current depth of cut and the current rpm. On the basis ofthe aforesaid inputs, the historical map generator 748 creates aplurality of historical UDC presence/absence (HUPA) maps 750. It is aparticular feature of an embodiment of the present invention that theHUPA maps 750 include depth of cut and rpm pairs for most or allinstances where UDC did not occur. Preferably, but not necessarily, theHUPA maps 750 also include depth of cut and rpm pairs for most or allinstances where UDC did occur.

For the purposes of the description which follows, each HUPA map 750 isspecific to a given combination of workpiece material and type of tool,here designated WMTT and may be additionally specific to a given machinetool, here designated WMTTMT.

In accordance with one embodiment of the invention, similarly to thecase described above with reference to FIGS. 1A-1C, each HUPA map 750 ismachine tool specific as well and thus specific HUPA maps 750 aregenerated for each of the multiple machine tools in a shop. This isparticularly relevant when the various CNC machining centers 725 are ofdifferent types or have different overall operating characteristics,which render them suitable for different machining tasks. In such acase, the generation of machine tool specific HUPA maps 750 is useful inenabling production planning and allocation of machining resources.

In accordance with another embodiment of the invention, as distinguishedfrom the case described above with reference to FIGS. 1A-1C, non-machinetool specific HUPA (NMTSHUPA) maps 750 may be generated based onempirical data received from multiple machine tools having at least apredetermined level of similarity. For example, the multiple machinetools whose empirical data is used for generating a NMTSHUPA map 750 maybe manufactured by different manufacturers but have the same power andspeed capabilities. In another example, the multiple machine tools whoseempirical data is used for generating a NMTSHUPA map 750 may bemanufactured by the same manufacturer and have similar mechanicalstructures but have different spindle ratings. In a further example, themultiple machine tools whose empirical data is used for generating aNMTSHUPA map 750 may be manufactured by the same manufacturer ordifferent manufacturers and have similar mechanical structures,rigidity, and ranges of movements along their various axes.

It is appreciated that separate NMTSHUPA maps 750 may be generated for agiven WMTT based on various additional parameters including, for examplea level of tool wear or a different threshold applicable to thedefinition of UDC. It is further appreciated that even more specificNMTSHUPA maps 750 may be generated for a given WMTT for each combinationof a plurality of selectable machining parameters, for example, thecorner radius of each cutting edge, the rake angle of each cutting edge,the flute helix angle of each cutting edge, the number of layers ofinserts in an insert cutter, the number of inserts in each layer, thedimensions of each insert and the extent of overlap between layers ofinserts.

It is appreciated that preferably, NMTSHUPA maps 750 are built up basedon actual recorded microphone inputs from actual past machiningoperations on multiple workpieces. Thus, similarly to that describedhereinabove with reference to FIG. 4 , initially only a few pixels,representing specific depth of cut and rpm pairings, appear, heretypically represented by a black solid pixel indicating the absence ofUDC and preferably also by a cross-hatched pixel indicating the presenceof UDC. These pairings represent actual depth of cut and rpm pairings ofhistorical machining operations for a given type of tool and materialusing one or more CNC machining centers 725.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining carried out by CNC machining centers 725,more and more pixels in each HUPA map 750 are filled in, typically by ablack solid pixel indicating the absence of UDC or by a cross-hatchedpixel indicating the absence of UDC. The latest NMTSHUPA map 750 foreach different WMTT is preferably stored in HED database 736 and isautomatically consulted by the MCNCPG software 730, such as theIMACHINING® software, to validate the acceptability of the CNC programgenerated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 730 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 730 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 730 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 730 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 730 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 730 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 730 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 730 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 730        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 730 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 730 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        730 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 730 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 730; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 730.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software730 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 730, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software730 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 730, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 730.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 734 is provided, the TPG software732 provides a proposed tool path output, defining for each machiningoperation: particulars of the tool, the depth of cut, the nominal feedspeed and the tool trajectory, to the CCM software 734. The CCM software734 provides, on the basis of the proposed tool path output, a cuttingconditions output, defining for each machining operation: toolengagement angles for each point along the trajectory, the feed speed ateach point along the trajectory and the rpm. The CCM software 734 and/orthe TPG software 732 provide a UDC avoidance input to MHBUCA module 710including for each machining operation: the WMTTMT, the depth of cut,and the rpm.

MHBUCA module 710 consults HED database 736, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described hereinabove, nochange in the rpm is made by MHBUCA module 710.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described hereinabove, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 710, basedon the HED database 736, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTTMT. Preferably, an rpm which is higher than theUDC-problematic rpm is selected, however, there may be instances wherean rpm which is lower than the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 710, theproposed replacement rpm is output to the CCM software 734, whichconfirms that the replacement rpm is suitable for use for the givenWMTTMT under the cutting conditions already established by the CCMsoftware 734 for the given operation. This confirmation is provided bythe CCM software 734 to the MCNCPG software 730, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller724 of a given machine tool, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 734 is not provided, the MCNCPG software 730provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTTMT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 710.

MHBUCA module 710 consults HED database 736, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described hereinabove, nochange in the rpm is made by MHBUCA module 710.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described hereinabove, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 710, basedon the HED database 736, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTTMT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTTMT. Preferably, an rpm which is higher than theUDC-problematic rpm is selected, however, there may be instances wherean rpm which is lower than the UDC-problematic rpm is selected.

Additionally or alternatively, where multiple machine tools having atleast somewhat different characteristics are suitable and available fora given machining operation for a given WMTT and where HED database 736contains multiple HUPA maps 750 corresponding to different availablemachine tools, the MHBUCA module 710 may select one or more specificmachine tools from among all of the suitable and available machine toolsto carry out the machining operation. Furthermore, the MHBUCA module 710may select one or more specific machine tools from among all of thesuitable and available machine tools which will carry out the givenmachining operation in an optimal manner not only from the perspectiveof UDC avoidance but also from the perspective of machining efficiency,such as machining cycle time.

Where a change in the rpm is proposed by the MHBUCA module 710, theproposed replacement rpm is output to the MCNCPG software 730, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 730 provides a final UDC-free CNC program ready for loadingonto the CNC controller 724 of each machine tool prior to commencementof machining.

It is appreciated that this embodiment of the present invention operatesinitially in a learning mode wherein most of the pixels in the HUPA maps750, each representing a depth of cut and rpm pairing for a givenmachine, tool and workpiece material, are not yet marked as UDC orUDC-free pixels. In such cases, there are expected to be many situationsin which a proposed pair is neither validated nor disallowed and wherethe system carries out machining without a definite prediction regardingUDC. It will be appreciated by persons skilled in the art that thelikelihood that the system will be able to accurately predict whether ornot a given proposed non-marked pixel will be UDC-free depends on thedensity of marked pixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut and rpm pair is neither validatednor disallowed, the MCNCPG software 730 provides a final CNC programusing the proposed depth of cut/rpm pair, ready for loading onto a givenCNC controller 724 prior to commencement of machining.

It is a particular feature of the embodiment of the present inventiondescribed hereinabove with reference to FIG. 2B, that where the proposeddepth of cut/rpm pair is neither validated nor disallowed based onmachine tool specific HUPA maps 750, MHBUCA module 710 may consultnon-machine tool specific HUPA maps 750 in HED database 736, which,being based on a relatively large number of machining events may besubstantially more populated than corresponding machine tool specificHUPA maps 750.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software730 in CNCPGCAM server 720, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 750, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 750 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 750 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 750, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 2C, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system 800 andmethodology including a milling history-based undesirable chatter (UDC)avoidance (MHBUCA) module 810, constructed and operative in accordancewith yet another embodiment of the present invention. The embodiment ofFIG. 2C is preferably a 3D system although alternatively it may be a2.5D system. A CNC program generation CAM (CNCPGCAM) server 820 ispreferably resident on the cloud and provides a CNC program, which isemployed by one or more CNC controller 822 to operate one or more of aplurality of CNC milling machine such as CNC machining center 824. TheCNC program includes inter alia, a tool path, spindle on/off commands,tool change commands, rpm commands, feed commands and coolant on/offcommands. An operator may control operation of system 800 locally orremotely via a wireless device 826, such as an I-PAD.

The CNC program generation CAM server 820 may be any suitable CNCprogram generation CAM server and is preferably a server hosting millingCNC program generation (MCNCPG) software 830. The MCNCPG software 830preferably includes tool path generation (TPG) software 832 and cuttingconditions management (CCM) software 834.

A preferred type of milling CNC program generation (MCNCPG) software 830is Solidcam™ milling CNC program generation software and includescutting conditions management (CCM) software 834 embodied in anIMACHINING® module, which provides an output including a set of cuttingconditions suitable for each point along a given toolpath. Solidcam™milling CNC program generation software is commercially available fromthe assignee of the present application, SolidCAM Ltd. of Or-Yehuda,Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 2C is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present inventionMHBUCA module 810 is preferably resident on the cloud and stores andutilizes pairs of depth of cut and rpm at which undesirable chatter(UDC) did not occur for past machining, using at least one given type ofmilling machine, at least one given type of cutting tool and at leastone given type of workpiece material, and thus provides undesirablechatter (UDC) avoidance as part of the CNC program generation.

MHBUCA module 810 employs empirical data obtained from machiningactivity on at least one workpiece material at an earlier time, whichdata is stored in a historical empirical data (HED) database 836,associated therewith, to generate and store historical mappingsindicating which pairings of depth of cut and rpm produce or do notproduce UDC when at least one given type of tool is used to machine atleast one given type of workpiece material. HED database 836 ispreferably also located on the cloud. It is a particular feature of anembodiment of the present invention that the MHBUCA module 110 storesand utilizes pairs of depth of cut and rpm at which undesirable chatter(UDC) did not occur for past machining, using at least one given type ofmilling machine, at least one given type of cutting tool and at leastone given type of workpiece material, in providing chatter avoidance.

In the illustrated embodiment of FIG. 2C, the historical empirical datais derived from earlier operation of one or more CNC machining centers824 and is employed to generate subsequent UDC-free CNC programs forsuch CNC machining center 824, such that subsequent milling operation ofthe CNC machining centers 824 based on the CNC programs thus generatedavoids UDC.

As in the embodiments of FIGS. 1A-2B, at least one microphone 840 ispreferably mounted on each CNC machining center 824 and its output issupplied to microphone input circuitry 842, which preferably includesspectral analysis functionality 844. Microphone input circuitry 842forms part of MHBUCA module 810, which preferably operates as describedhereinabove and also includes a UDC identifier 846 which outputs to ahistorical map generator 848, which, as described hereinabove, creates aplurality of historical UDC presence/absence (HUPA) maps 850, asdescribed hereinabove.

Historical map generator 848 receives a UDC presence input from the UDCidentifier 846 having a time stamp and also receives, from each CNCcontroller 822 of a plurality of corresponding CNC machining centers824, at least one input providing current information indicating thetool currently being used in milling, the workpiece material beingmilled, the current depth of cut and the current rpm. On the basis ofthe aforesaid inputs, the historical map generator 848 creates aplurality of historical UDC presence/absence (HUPA) maps 850. It is aparticular feature of an embodiment of the present invention that theHUPA maps 850 include depth of cut and rpm pairs for most or allinstances where UDC did not occur. Preferably, but not necessarily, theHUPA maps 850 also include depth of cut and rpm pairs for most or allinstances where UDC did occur.

For the purposes of the description which follows, each HUPA map 850 isspecific to a given combination of workpiece material and type of tool,here designated WMTT and may be additionally specific to a given machinetool, here designated WMTTMT.

In accordance with one embodiment of the invention, similarly to thecase described above with reference to FIGS. 1A-1C, each HUPA map 850 ismachine tool specific as well and thus specific HUPA maps 850 aregenerated for each of the multiple machine tools in a shop. This isparticularly relevant when the various CNC machining centers 824 are ofdifferent types or have different overall operating characteristics,which render them suitable for different machining tasks. In such acase, the generation of machine tool specific HUPA maps 850 is useful inenabling production planning and allocation of machining resources.

In accordance with another embodiment of the invention, as distinguishedfrom the case described above with reference to FIGS. 1A-1C, non-machinetool specific HUPA (NMTSHUPA) maps 850 may be generated based onempirical data received from multiple machine tools having at least apredetermined level of similarity. For example, the multiple machinetools whose empirical data is used for generating a NMTSHUPA map 850 maybe manufactured by different manufacturers but have the same power andspeed capabilities. In another example, the multiple machine tools whoseempirical data is used for generating a NMTSHUPA map 850 may bemanufactured by the same manufacturer and have similar mechanicalstructures but have different spindle ratings. In a further example, themultiple machine tools whose empirical data is used for generatingNMTSHUPA map 850 may be manufactured by the same manufacturer ordifferent manufacturers and have similar mechanical structures,rigidity, and ranges of movements along their various axes.

It is appreciated that separate NMTSHUPA maps 850 may be generated for agiven WMTT based on various additional parameters including, forexample, a level of tool wear or a different threshold applicable to thedefinition of UDC. It is further appreciated that even more specificNMTSHUPA maps 850 may be generated for a given WMTT for each combinationof a plurality of selectable machining parameters, for example, thecorner radius of each cutting edge, the rake angle of each cutting edge,the flute helix angle of each cutting edge, the number of layers ofinserts in an insert cutter, the number of inserts in each layer, thedimensions of each insert and the extent of overlap between layers ofinserts.

It is appreciated that preferably, HUPA maps 850 are built up based onactual recorded microphone inputs from actual past machining operationson multiple workpieces. Thus, similarly to that described hereinabovewith reference to FIG. 4 , initially only a few pixels, representingspecific depth of cut and rpm pairings, appear, here typicallyrepresented by a black solid pixel indicating the absence of UDC andpreferably also by a cross-hatched pixel indicating the presence of UDC.These pairings represent actual depth of cut and rpm pairings ofhistorical machining operations for a given type of tool and materialusing one or more CNC machining centers 824.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining carried out by CNC machining centers 824,more and more pixels in each HUPA map 850 are filled in, typically by ablack solid pixel indicating the absence of UDC or by a cross-hatchedpixel indicating the presence of UDC. The latest HUPA map 850 for eachdifferent WMTT is preferably stored in HED database 836 and isautomatically consulted by the MCNCPG software 830, such as theIMACHINING® software, to validate the acceptability of the CNC programgenerated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 830 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 830 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 830 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 830 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 830 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 830 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 830 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 830 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 830        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 830 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 830 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        830 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 830 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 830; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 830.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software830 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 830, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software830 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 830, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 830.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 834 is provided, the TPG software832 provides a proposed tool path output, defining for each machiningoperation: particulars of the tool, the depth of cut, the nominal feedspeed and the tool trajectory, to the CCM software 834. The CCM software834 provides, on the basis of the proposed tool path output, a cuttingconditions output, defining for each machining operation: toolengagement angles for each point along the trajectory, the feed speed ateach point along the trajectory and the rpm. The CCM software 834 and/orthe TPG software 832 provide a UDC avoidance input to MHBUCA module 810including for each machining operation: the WMTTMT, the depth of cut,and the rpm.

MHBUCA module 810 consults HED database 836, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described hereinabove, nochange in the rpm is made by MHBUCA module 810.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 810, basedon HED database 836, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTTMT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 810, theproposed replacement rpm is output to the CCM software 834, whichconfirms that the replacement rpm is suitable for use for the givenWMTTMT under the cutting conditions already established by the CCMsoftware 834 for the given operation. This confirmation is provided bythe CCM software 834 to the MCNCPG software 830, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller822 of a given machine tool, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 834 is not provided, the MCNCPG software 830provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTTMT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 810.

MHBUCA module 810 consults HED database 836, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTTMT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTTMT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT, or are validated as described hereinabove, nochange in the rpm is made by MHBUCA module 810.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTTMT, or are disallowed as described hereinabove, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 810, basedon HED database 836, which contains the historical mappings indicatingwhich pairings of depth of cut and rpm did not historically produce UDCfor the given WMTTMT and preferably also indicating which pairings ofdepth of cut and rpm did historically produce UDC for the given WMTTMT.Preferably, an rpm which is higher than the UDC-problematic rpm isselected, however, there may be instances where an rpm which is lowerthan the UDC-problematic rpm is selected.

Additionally or alternatively, where multiple machine tools having atleast somewhat different characteristics are suitable and available fora given machining operation for a given WMTT and where HED database 836contains multiple HUPA maps 850 corresponding to different availablemachine tools, the MHBUCA module 810 may select one or more specificmachine tools from among all of the suitable and available machine toolsto carry out the machining operation. Furthermore, the MHBUCA module 810may select one or more specific machine tools from among all of thesuitable and available machine tools which will carry out the givenmachining operation in an optimal manner not only from the perspectiveof UDC avoidance but also from the perspective of machining efficiency,such as machining cycle time.

Where a change in the rpm is proposed by the MHBUCA module 810, theproposed replacement rpm is output to the MCNCPG software 830, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 830 provides a final UDC-free CNC program ready for loadingonto the CNC controller 822 of each machine tool prior to commencementof machining.

It is appreciated that this embodiment of the present invention operatesinitially in a learning mode wherein most of the pixels in the HUPA maps850, each representing a depth of cut and rpm pairing for a givenmachine, tool and workpiece material, are not yet marked as UDC orUDC-free pixels. In such cases, there are expected to be many situationsin which a proposed pair is neither validated nor disallowed and wherethe system carries out machining without a definite prediction regardingUDC. It will be appreciated by persons skilled in the art that thelikelihood that the system will be able to accurately predict whether ornot a given proposed non-marked pixel will be UDC-free depends on thedensity of marked pixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 830 provides a final CNC program usingthe proposed depth of cut/rpm pair, ready for loading onto a given CNCcontroller 822 prior to commencement of machining.

It is a particular feature of the embodiment of the present inventiondescribed hereinabove with reference to FIG. 2C, that where the proposeddepth of cut/rpm pair is neither validated nor disallowed based onmachine tool specific HUPA maps 850, MHBUCA module 810 may consultnon-machine tool specific HUPA maps 850 in HED database 836, which,being based on a relatively large number of machining events, may besubstantially more populated than corresponding machine tool specificHUPA maps 850.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software830 in CNCPGCAM server 820, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 850, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 850 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 850 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 850, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 3A, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system andmethodology employing a multiplicity of machine tools, typically ofvarious different types, and preferably including a plurality of millinghistory-based undesirable chatter avoidance modules, at least one ofwhich is resident on at least one CNC program generation CAM server,constructed and operative in accordance with yet another embodiment ofthe present invention.

FIG. 3A shows a milling CNC program generation CAM and CNC millingsystem 900 and methodology employing a large number of machine tools,typically of different types, made by different manufacturers and heredesignated by reference numerals 901, 902, 903, 904, 905, 906, 907, 908,and 909. The machine tools are distributed over a multiplicity ofworkshops, which are located geographically throughout the world. In onerealization of this embodiment of the invention, the machine tools areall managed by a single organization, such as, for example, an aircraftmanufacturing company, which manufactures aircraft parts in multiplefacilities throughout the world. In another realization of thisembodiment of the invention the machine tools are managed by differententities.

System 900 preferably comprises one or more milling history-basedundesirable chatter avoidance (MHBUCA) module 910, constructed andoperative in accordance with one embodiment of the present invention,preferably resident on one or more CNC program generation CAM (CNCPGCAM)server 920. The CNCPGCAM servers 920 each provide a CNC program which issupplied to at least one CNC controller 922 of one or more CNC millingmachines, such as CNC machining centers 924. The CNC program preferablyincludes, inter alia, a tool path, spindle on/off commands, tool changecommands, rpm commands, feed commands and coolant on/off commands.

In one realization of this embodiment of the invention, eachorganization may have one or more MHBUCA module 910 and correspondingCNCPGCAM servers 920, which communicate only with machine tools managedby that organization. In another realization of this embodiment of theinvention one or more MHBUCA modules 910 and corresponding CNCPGCAMservers 920 may be provided, which may communicate with machine tools ofmore than one organization or entity.

Each CNCPGCAM server 920 may be any suitable CNC program generation CAMserver and is preferably a server hosting milling CNC program generation(MCNCPG) software 930. The MCNCPG software 930 preferably includes toolpath generation (TPG) software 932 and cutting conditions management(CCM) software 934.

A preferred type of MCNCPG software 930 is Solidcam™ milling CNC programgeneration software and includes cutting conditions management software934 embodied in an IMACHINING® module, which provides an outputincluding a set of cutting conditions suitable for each point along agiven toolpath. Solidcam™ milling CNC program generation software iscommercially available from the assignee of the present application,SolidCAM Ltd. of Or-Yehuda, Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 3A is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present invention,MHBUCA module 910 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides undesirable chatter (UDC) avoidance as part of the CNC programgeneration.

In the embodiment of FIG. 3A, the MCNCPG software 930 in each CNCPGCAMserver 920 is located in an engineering room wherein productionengineers interact with the CNCPGCAM server 920 to generate the CNCprograms which are downloaded to the CNC controller 922 of each one ofmultiple CNC machining centers 924, which may or may not be located at acommon location.

In accordance with this embodiment of the invention, the MHBUCA module910 employs empirical data obtained from machining activity carried outon multiple machines, at various disparate locations, on at least oneworkpiece material at an earlier time, which data is stored in at leastone historical empirical data (HED) database 936, to generate and storehistorical mappings indicating which pairings of depth of cut and rpmproduce or do not produce tool undesirable chatter (UDC) when at leastone given type of tool is used to machine at least one given type ofworkpiece material. It is a particular feature of an embodiment of thepresent invention that the MHBUCA module 910 stores and utilizes pairsof depth of cut and rpm at which undesirable chatter (UDC) did not occurfor past machining, using at least one given type of milling machine, atleast one given type of cutting tool and at least one given type ofworkpiece material, in providing chatter avoidance.

In one realization of this embodiment, each MHBUCA module 910 receivesempirical data originating from machines all belonging to a singleorganization. In another realization of this embodiment, at least oneMHBUCA module 910 receives empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboverealizations, each MHBUCA module 910 receives empirical data originatingfrom machines of the same type, manufactured by a same manufacturer oralternatively receives empirical data from machines of different types,manufactured by a same manufacturer. As a further alternative, at leastone MHBUCA module 910 receives empirical data from machines of differenttypes, manufactured by different manufacturers.

In a further realization of this embodiment of the invention, which isnot mutually exclusive to the realizations described in the precedingparagraph, each organization may have one or more MHBUCA module 910 andcorresponding CNCPGCAM servers 920, which may provide NMTSHUPA maps foruse by machine tools managed by that organization. In another furtherrealization of this embodiment of the invention, which is not mutuallyexclusive to the realizations described in the preceding paragraph, oneor more MHBUCA modules 910 and corresponding CNCPGCAM servers 920 may beprovided, which may provide NMTSHUPA maps for use by machine tools ofmore than one organization or entity.

In the illustrated embodiment of FIG. 3A, the historical empirical datais derived from earlier operation of one or more CNC machining center924 and is employed to generate subsequent UDC-free CNC programs for oneor more CNC machining center 924, such that milling operation of the CNCmachining centers 924 based on the CNC programs thus generated avoidsUDC.

In accordance with a preferred embodiment of the invention, one or moremicrophone 960 is mounted on each CNC machining center 924, such aswithin the machining chamber 962 of the CNC machining center 924 or onan outer housing thereof. Each CNC machining center 924 also typicallyincludes CNC controller 922. An output of microphone 960 is supplied tomicrophone input circuitry 970, and which may include spectral analysisfunctionality 972, such as Fast Fourier Transformation (FFT)functionality, which transforms the microphone output, which is in thetime domain, to the frequency domain.

An output of the microphone input circuitry 970, which preferablyincludes the spectral analysis functionality 972, is in the frequencydomain and is supplied to a UDC identifier 980 which identifies peaks inthe frequency domain, which are not coincident with any of the harmonicpeaks characteristic of the tooth passing frequency. If such peaksexceed a given height, corresponding to a predetermined amplitudethreshold characterizing UDC, the presence of UDC is identified.

In accordance with one embodiment of the invention, microphone inputcircuitry 970, spectral analysis functionality 972 and UDC identifier980 may be provided at each machine tool. Alternatively, the microphoneinput circuitry 970 may be provided at each machine tool and thespectral analysis functionality 972 and UDC identifier 980 may beprovided as part of at least one MHBUCA module 910. As a furtheralternative, microphone input circuitry 970, spectral analysisfunctionality 972 and UDC identifier 980 may all be provided as part ofat least one MHBUCA module 910.

A historical map generator 990 receives a UDC presence input from atleast one UDC identifier 980 having a time stamp and also receives fromthe CNC controller 922 of the corresponding CNC machining center 924 atleast one input providing current information indicating the toolcurrently being used in milling, the workpiece material being milled,the current depth of cut and the current rpm. On the basis of theaforesaid inputs, the historical map generator 990 creates a pluralityof historical UDC presence/absence (HUPA) maps 1000. It is a particularfeature of an embodiment of the present invention that the HUPA maps1000 include depth of cut and rpm pairs for most or all instances whereUDC did not occur. Preferably, but not necessarily, the HUPA maps 1000also include depth of cut and rpm pairs for most or all instances whereUDC did occur.

In accordance with one embodiment of the invention, historical mapgenerator 990 receives a UDC presence input from at least one UDCidentifier 980 based on empirical data originating from machines allbelonging to a single organization. In another embodiment, historicalmap generator 990 receives a UDC presence input from at least one UDCidentifier 980 based on empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboveembodiments, historical map generator 990 receives a UDC presence inputfrom at least one UDC identifier 980 based on empirical data originatingfrom machines of the same type, manufactured by a same manufacturer oralternatively based on empirical data from machines of different types,manufactured by a same manufacturer. As a further alternative,historical map generator 990 receives a UDC presence input from at leastone UDC identifier 980 based on empirical data from machines ofdifferent types, manufactured by different manufacturers.

In accordance with an embodiment of the present application, each HUPAmap 1000 is specific at least to a given combination of workpiecematerial and type of tool, here designated WMTT.

In accordance with one embodiment of the invention, at least one HUPAmap 1000 is based on empirical data originating from machines allbelonging to a single organization. In another embodiment, at least oneHUPA map 1000 is based on empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboveembodiments, at least one HUPA map 1000 is based on empirical dataoriginating from machines of the same type, manufactured by a samemanufacturer or alternatively based on empirical data from machines ofdifferent types, manufactured by a same manufacturer. As a furtheralternative, at least one HUPA map 1000 is based on empirical data frommachines of different types, manufactured by different manufacturers.

In accordance with one embodiment of the invention, similarly to thecase described above with reference to FIGS. 1A-1C, each HUPA map 1000is machine tool specific as well and thus HUPA maps 1000 are generatedfor each of the multiple machine tools communicating with the system.This is particularly relevant when the various CNC machining centers 924are of different types or have different overall operatingcharacteristics, which render them suitable for different machiningtasks. In such a case, the generation of machine tool specific HUPA maps1000 is useful in enabling production planning and allocation ofmachining resources. The tool specific HUPA maps 1000 are each based onempirical data relating to a combination of workpiece material, type oftool and machine tool, here designated WMTTMT.

In accordance with another embodiment of the invention, as distinguishedfrom the case described above with reference to FIGS. 1A-1C, non-machinetool specific HUPA (NMTSHUPA) maps 1000 may be generated based onempirical data received from multiple machine tools having at least apredetermined level of similarity. For example, the multiple machinetools whose empirical data is used for generating a NMTSHUPA map 1000may be manufactured by different manufacturers but have the same powerand speed capabilities. In another example, the multiple machine toolswhose empirical data is used for generating a NMTSHUPA map 1000 may bemanufactured by the same manufacturer and have similar mechanicalstructures but have different spindle ratings. In a further example, themultiple machine tools whose empirical data is used for generating aNMTSHUPA map 1000 may be manufactured by the same manufacturer ordifferent manufacturers and have similar mechanical structures,rigidity, and ranges of movements along their various axes.

It is appreciated that separate NMTSHUPA maps 1000 may be generated fora given WMTT based on various additional parameters including, forexample, a level of tool wear or a different threshold applicable to thedefinition of UDC. It is further appreciated that even more specificNMTSHUPA maps 1000 may be generated for a given WMTT for eachcombination of a plurality of selectable machining parameters, forexample, the corner radius of each cutting edge, the rake angle of eachcutting edge, the flute helix angle of each cutting edge, the number oflayers of inserts in an insert cutter, the number of inserts in eachlayer, the dimensions of each insert and the extent of overlap betweenlayers of inserts.

It is appreciated that preferably, the NMTSHUPA maps 1000 are built upbased on actual recorded microphone inputs from actual past machiningoperations on multiple workpieces. Thus, similarly to that describedhereinabove with reference to FIG. 4 , initially only a few pixels,representing specific depth of cut and rpm pairings, appear, heretypically represented by a black solid pixel indicating the absence ofUDC and preferably also by a cross-hatched pixel indicating the presenceof UDC. These pairings represent actual depth of cut and rpm pairings ofhistorical machining operations for a given type of tool and materialusing one or more CNC machining centers 924.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining carried out by CNC machining centers 924,more and more pixels in each NMTSHUPA map 1000 are filled in, typicallyby a black solid pixel indicating the absence of UDC or by across-hatched pixel indicating the presence of UDC. The latest NMTSHUPAmap 1000 for each different WMTT is preferably stored in historicalempirical data (HED) database 936 and is automatically consulted by theMCNCPG software 930, such as the IMACHINING® software, to validate theacceptability of the CNC program generated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 930 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 930 corresponds to a black solid pixel, indicating that        historically UDC was not encountered, the depth of cut/rpm pair        is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 930 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 930 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 930 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 930 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 930 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 930 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 930        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 930 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 930 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        930 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 930 is neither validated nor disallowed, the system may proceedalong one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 930; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 930.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software930 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 930, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software930 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 930, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 930.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 934 is provided, the TPG software932 provides a proposed tool path output, defining for each machiningoperation: particulars of the tool, the depth of cut, the nominal feedspeed and the tool trajectory, to the CCM software 934. The CCM software934 provides, on the basis of the proposed tool path output, a cuttingconditions output, defining for each machining operation: toolengagement angles for each point along the trajectory, the feed speed ateach point along the trajectory and the rpm. The CCM software 934 and/orthe TPG software 932 provide an undesirable chatter (UDC) avoidanceinput to milling history-based undesirable chatter (UDC) avoidance(MHBUCA) module 910 including for each machining operation: the WMTTMT,the depth of cut, and the rpm.

MHBUCA module 910 consults HED database 936, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 910.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described hereinabove, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 910, basedon the HED database 936, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTT. Preferably, an rpm which is higher than the UDC-problematicrpm is selected, however, there may be instances where an rpm which islower than the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 910, theproposed replacement rpm is output to the CCM software 934, whichconfirms that the replacement rpm is suitable for use for the given WMTTunder the cutting conditions already established by the CCM software 934for the given operation. This confirmation is provided by the CCMsoftware 934 to the MCNCPG software 930, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller922 of a given machine tool, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 934 is not provided, the MCNCPG software 930provides a proposed CNC program output, defining for each machiningoperation: the WMTT, the depth of cut, the rpm, the feed speeds and thetool trajectory in response to a user-defined nominal cutting conditionsinput, defining for each machining operation along a proposed tooltrajectory: nominal tool engagement angle, nominal feed speed, depth ofcut and rpm.

The particulars of the WMTT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 910.

MHBUCA module 910 consults HED database 936, associated therewith, whichcontains the historical mappings indicating which pairings of depth ofcut and rpm do not produce UDC for the given WMTT and preferably alsowhich pairings of depth of cut and rpm do produce UDC for the givenWMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 910.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described hereinabove, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 910, basedon the HED database 936, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTT. Preferably, an rpm which is higher than the UDC-problematicrpm is selected, however, there may be instances where an rpm which islower than the UDC-problematic rpm is selected.

Additionally or alternatively, where multiple machine tools having atleast somewhat different characteristics are suitable and available fora given machining operation for a given WMTT and where HED database 936contains multiple HUPA maps 1000 corresponding to different availablemachine tools, the MHBUCA module 910 may select one or more specificmachine tools from among all of the suitable and available machine toolsto carry out the machining operation. Furthermore, the MHBUCA module 910may select one or more specific machine tools from among all of thesuitable and available machine tools which will carry out the givenmachining operation in an optimal manner not only from the perspectiveof UDC avoidance but also from the perspective of machining efficiency,such as machining cycle time.

Where a change in the rpm is proposed by the MHBUCA module 910, theproposed replacement rpm is output to the MCNCPG software 930, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 930 provides a final UDC-free CNC program ready for loadingonto the CNC controller 922 prior to commencement of machining.

It is appreciated that this embodiment of the present invention operatesinitially in a learning mode wherein most of the pixels in the HUPA maps1000, each representing a depth of cut and rpm pairing for a givenmachine, tool and workpiece material, are not yet marked as UDC orUDC-free pixels. In such cases, there are expected to be many situationsin which a proposed pair is neither validated nor disallowed and wherethe system carries out machining without a definite prediction regardingUDC. It will be appreciated by persons skilled in the art that thelikelihood that the system will be able to accurately predict whether ornot a given proposed non-marked pixel will be UDC-free depends on thedensity of marked pixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 930 provides a final CNC program usingthe proposed depth of cut/rpm pair, ready for loading onto the CNCcontroller 922 prior to commencement of machining.

It is a particular feature of the embodiment of the present inventiondescribed hereinabove with reference to FIG. 3A, that where the proposeddepth of cut/rpm pair is neither validated nor disallowed based onmachine tool specific HUPA maps 1000, MHBUCA module 910 may consultnon-machine tool specific HUPA maps 1000 in HED database 936, which,being based on a relatively large number of machining events, may besubstantially more populated than corresponding machine tool specificHUPA maps 1000.

It is a particular feature of an embodiment of the present inventionthat various types of HUPA maps 1000 may be provided. These include, forexample:

-   -   A. a machine tool specific HUPA map 1000 which is based on        historical empirical data from a given machine tool;    -   B. a machine tool type specific HUPA map 1000, which is based on        historical empirical data received from multiple machine tools        of a given type;    -   C. a machine tool manufacturer specific HUPA map 1000, which is        based on historical empirical data received from multiple        machine tools made by a given manufacturer;    -   D. a machine tool characteristic specific HUPA map 1000, which        is based on historical empirical data received from multiple        machine tools having at least one given structural or        operational characteristic.

Various additional types of HUPA maps 1000 may be additionally oralternatively provided.

It is appreciated that type A HUPA maps 1000 are the most reliable forUDC prediction for the given machine tool to which they relate and thattypically type B—type D HUPA maps 1000 are typically less reliable forUDC prediction. Accordingly, normally MHBUCA module 910 will inquire asto whether a pixel associated with a given depth of cut/rpm is indicatedto be UDC free on the type A HUPA map 1000 relating to the given machinetool. If a pixel associated with a given depth of cut/rpm is indicatedto be UDC free on the type A HUPA map 1000, no further inquiry isrequired.

If however, the historical map generator 990 is at a relatively earlylearning phase with respect to the relevant type A HUPA map 1000 andthus a pixel associated with a given depth of cut/rpm and pixels havingsimilar rpms for the same depth of cut are not indicated to be UDC freeon the type A HUPA map 1000, the MHBUCA module 910 may consider HUPAmaps 1000 of types B, C and D or other suitable HUPA maps 1000.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software930 in CNCPGCAM server 920, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 1000, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 1000 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 1000 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 1000, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 3B, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system andmethodology employing a multiplicity of machine tools, typically ofvarious different types, and preferably including a plurality of millinghistory-based undesirable chatter avoidance modules, at least one ofwhich is resident on at least one CNC program generation CAM server.

FIG. 3B shows a milling CNC program generation CAM and CNC millingsystem 1100 and methodology employing a large number of machine tools,typically of different types, made by different manufacturers and heredesignated by reference numerals 1101, 1102, 1103, 1104, 1105, 1106,1107, 1108, and 1109. The machine tools are distributed over amultiplicity of workshops, which are located geographically throughoutthe world. In one realization of this embodiment of the invention, themachine tools are all managed by a single organization, such as, forexample, an aircraft manufacturing company, which manufactures aircraftparts in multiple facilities throughout the world. In anotherrealization of this embodiment of the invention the machine tools aremanaged by different entities.

System 1100 preferably comprises multiple milling history-basedundesirable chatter avoidance (MHBUCA) modules 1110, constructed andoperative in accordance with one embodiment of the present invention,preferably resident on multiple CNCPGCAM servers 1120. The CNCPGCAMservers 1120 each provide a CNC program which is supplied to at leastone CNC controller 1122 of one or more CNC milling machines, such asmachining centers 1124. The CNC program preferably includes, inter alia,a tool path, spindle on/off commands, tool change commands, rpmcommands, feed commands and coolant on/off commands.

In one realization of this embodiment of the invention, eachorganization may have one or more MHBUCA module 1110 and correspondingCNCPGCAM servers 1120, which receive empirical data only from machinetools managed by that organization. In another realization of thisembodiment of the invention one or more MHBUCA modules 1110 andcorresponding CNCPGCAM servers 1120 may be provided, which may receiveempirical data from machine tools of more than one organization orentity.

In a further realization of this embodiment of the invention, which isnot mutually exclusive to the realizations described in the precedingparagraph, each organization may have one or more MHBUCA module 1110 andcorresponding CNCPGCAM servers 1120, which may provide NMTSHUPA maps foruse by machine tools managed by that organization. In another furtherrealization of this embodiment of the invention, which is not mutuallyexclusive to the realizations described in the preceding paragraph, oneor more MHBUCA modules 1110 and corresponding CNCPGCAM servers 1120 maybe provided, which may provide NMTSHUPA maps for use by machine tools ofmore than one organization or entity.

Each CNCPGCAM server 1120 may be any suitable CNC program generation CAMserver and is preferably a server hosting milling CNC program generation(MCNCPG) software 1130. The MCNCPG software 1130 preferably includestool path generation (TPG) software 1132 and cutting conditionsmanagement (CCM) software 1134.

A preferred type of MCNCPG software 1130 is Solidcam™ milling CNCprogram generation software and includes cutting conditions managementsoftware 1134 embodied in an IMACHINING® module, which provides anoutput including a set of cutting conditions suitable for each pointalong a given toolpath. Solidcam™ milling CNC program generationsoftware is commercially available from the assignee of the presentapplication, SolidCAM Ltd. of Or-Yehuda, Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 3B is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present invention,MHBUCA module 1110 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides undesirable chatter (UDC) avoidance as part of the CNC programgeneration.

In the embodiment of FIG. 3B, the MCNCPG software 1130 and each CNCPGCAMserver 1120 are located on one or more computer, such as a portablenotebook computer 1135, used by production engineers to generate the CNCprograms which are downloaded to the CNC controller 1122 of each one ofmultiple CNC machining centers 1124, which may or may not be located ata common location.

In accordance with this embodiment of the invention, the MHBUCA module1110 employs empirical data obtained from machining activity carried outon multiple machines, at various disparate locations, on at least oneworkpiece material at an earlier time, which data is stored in at leastone historical empirical data (HED) database 1136, to generate and storehistorical mappings indicating which pairings of depth of cut and rpmproduce or do not produce tool undesirable chatter (UDC) when at leastone given type of tool is used to machine at least one given type ofworkpiece material. It is a particular feature of an embodiment of thepresent invention that the MHBUCA module 1110 stores and utilizes pairsof depth of cut and rpm at which undesirable chatter (UDC) did not occurfor past machining, using at least one given type of milling machine, atleast one given type of cutting tool and at least one given type ofworkpiece material, in providing chatter avoidance.

In one realization of this embodiment, each MHBUCA module 1110 receivesempirical data originating from machines all belonging to a singleorganization. In another realization of this embodiment, at least oneMHBUCA module 1110 receives empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboverealizations, each MHBUCA module 1110 receives empirical dataoriginating from machines of the same type, manufactured by a samemanufacturer or alternatively receives empirical data from machines ofdifferent types, manufactured by a same manufacturer. As a furtheralternative, at least one MHBUCA module 1110 receives empirical datafrom machines of different types, manufactured by differentmanufacturers.

In the illustrated embodiment of FIG. 3B, the historical empirical datais derived from earlier operation of one or more CNC machining center1124 and is employed to generate subsequent UDC-free CNC programs forone or more CNC machining center 1124, such that milling operation ofthe CNC machining centers 1124 based on the CNC programs thus generatedavoids UDC.

In accordance with a preferred embodiment of the invention, one or moremicrophone 1160 is mounted on each CNC machining center 1124, such aswithin the machining chamber 1162 of the CNC machining center 1124 or onan outer housing thereof. Each CNC machining center 1124 also typicallyincludes CNC controller 1122. An output of microphone 1160 is suppliedto microphone input circuitry 1170, and which may include spectralanalysis functionality 1172, such as Fast Fourier Transformation (FFT)functionality, which transforms the microphone output, which is in thetime domain, to the frequency domain.

An output of the microphone input circuitry 1170, which preferablyincludes the spectral analysis functionality 1172, is in the frequencydomain and is supplied to a UDC identifier 1180 which identifies peaksin the frequency domain, which are not coincident with any of theharmonic peaks characteristic of the tooth passing frequency. If suchpeaks exceed a given height, corresponding to a predetermined amplitudethreshold characterizing UDC, the presence of UDC is identified.

In accordance with one embodiment of the invention, microphone inputcircuitry 1170, spectral analysis functionality 1172 and UDC identifier1180 may be provided at each machine tool. Alternatively, the microphoneinput circuitry 1170 may be provided at each machine tool and thespectral analysis functionality 1172 and UDC identifier 1180 may beprovided as part of at least one MHBUCA module 1110. As a furtheralternative, microphone input circuitry 1170, spectral analysisfunctionality 1172 and UDC identifier 1180 may all be provided as partof at least one MHBUCA module 1110.

A historical map generator 1190 receives a UDC presence input from atleast one UDC identifier 1180 having a time stamp and also receives,from the CNC controller 1122 of the corresponding CNC machining center1124, at least one input providing current information indicating thetool currently being used in milling, the workpiece material beingmilled, the current depth of cut and the current rpm. On the basis ofthe aforesaid inputs, the historical map generator 1190 creates aplurality of historical UDC presence/absence (HUPA) maps 1195. It is aparticular feature of an embodiment of the present invention that theHUPA maps 1195 include depth of cut and rpm pairs for most or allinstances where UDC did not occur. Preferably, but not necessarily, theHUPA maps 1195 also include depth of cut and rpm pairs for most or allinstances where UDC did occur.

In accordance with one embodiment of the invention, historical mapgenerator 1190 receives a UDC presence input from at least one UDCidentifier 1180 based on empirical data originating from machines allbelonging to a single organization. In another embodiment, historicalmap generator 1190 receives a UDC presence input from at least one UDCidentifier 1180 based on empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboveembodiments, historical map generator 1190 receives a UDC presence inputfrom at least one UDC identifier 1180 based on empirical dataoriginating from machines of the same type, manufactured by a samemanufacturer or alternatively based on empirical data from machines ofdifferent types, manufactured by a same manufacturer. As a furtheralternative, historical map generator 1190 receives a UDC presence inputfrom at least one UDC identifier 1180 based on empirical data frommachines of different types, manufactured by different manufacturers.

In accordance with an embodiment of the present application, each HUPAmap 1195 is specific at least to a given combination of workpiecematerial and type of tool, here designated WMTT.

In accordance with one embodiment of the invention, at least one HUPAmap 1195 is based on empirical data originating from machines allbelonging to a single organization. In another embodiment, at least oneHUPA map 1195 is based on empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboveembodiments, at least one HUPA map 1195 is based on empirical dataoriginating from machines of the same type, manufactured by a samemanufacturer or alternatively based on empirical data from machines ofdifferent types, manufactured by a same manufacturer. As a furtheralternative, at least one HUPA map 1195 is based on empirical data frommachines of different types, manufactured by different manufacturers.

In accordance with one embodiment of the invention, similarly to thecase described above with reference to FIGS. 1A-1C, each HUPA map 1195is machine tool specific as well and thus HUPA maps 1195 are generatedfor each of the multiple machine tools communicating with the system.This is particularly relevant when the various CNC machining centers1124 are of different types or have different overall operatingcharacteristics, which render them suitable for different machiningtasks. In such a case, the generation of machine tool specific HUPA maps1195 is useful in enabling production planning and allocation ofmachining resources. The tool specific HUPA maps 1195 are each based onempirical data relating to a combination of workpiece material, type oftool and machine tool, here designated WMTTMT.

In accordance with another embodiment of the invention, as distinguishedfrom the case described above with reference to FIGS. 1A-1C, non-machinetool specific HUPA (NMTSHUPA) maps 1195 may be generated based onempirical data received from multiple machine tools having at least apredetermined level of similarity. For example, the multiple machinetools whose empirical data is used for generating a NMTSHUPA map 1195may be manufactured by different manufacturers but have the same powerand speed capabilities. In another example, the multiple machine toolswhose empirical data is used for generating a NMTSHUPA map 1195 may bemanufactured by the same manufacturer and have similar mechanicalstructures but have different spindle ratings. In a further example, themultiple machine tools whose empirical data is used for generating aNMTSHUPA map 1195 may be manufactured by the same manufacturer ordifferent manufacturers and have similar mechanical structures,rigidity, and ranges of movements along their various axes.

It is appreciated that separate NMTSHUPA maps 1195 may be generated fora given WMTT based on various additional parameters including, forexample, a level of tool wear or a different threshold applicable to thedefinition of UDC. It is further appreciated that even more specificNMTSHUPA maps 1195 may be generated for a given WMTT for eachcombination of a plurality of selectable machining parameters, forexample, the corner radius of each cutting edge, the rake angle of eachcutting edge, the flute helix angle of each cutting edge, the number oflayers of inserts in an insert cutter, the number of inserts in eachlayer, the dimensions of each insert and the extent of overlap betweenlayers of inserts.

It is appreciated that preferably, the NMTSHUPA maps 1195 are built upbased on actual recorded microphone inputs from actual past machiningoperations on multiple workpieces. Thus, similarly to that describedhereinabove with reference to FIG. 4 , initially only a few pixels,representing specific depth of cut and rpm pairings, appear, heretypically represented by a black solid pixel indicating the absence ofUDC and preferably also by a cross-hatched pixel indicating the presenceof UDC. These pairings represent actual depth of cut and rpm pairings ofhistorical machining operations for a given type of tool and materialusing one or more CNC machining centers 1124.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining carried out by CNC machining centers 1124,more and more pixels in each HUPA map 1195 are filled in, typically by ablack solid pixel indicating the absence of UDC or by a cross-hatchedpixel indicating the presence of UDC. The latest NMTSHUPA map 1195 foreach different WMTT is preferably stored in HED database 1136 and isautomatically consulted by the MCNCPG software 1130, such as theIMACHINING® software, to validate the acceptability of the CNC programgenerated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 1130 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 1130 corresponds to a black solid pixel, indicating        that historically UDC was not encountered, the depth of cut/rpm        pair is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 1130 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 1130 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 1130 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 1130 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 1130 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 1130 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 1130        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 1130 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 1130 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        1130 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 1130 is neither validated nor disallowed, the system mayproceed along one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 1130; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 1130.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software1130 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 1130, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software1130 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 1130, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 1130.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 1134 is provided, the TPGsoftware 1132 provides a proposed tool path output, defining for eachmachining operation: particulars of the tool, the depth of cut, thenominal feed speed and the tool trajectory, to the CCM software 1134.The CCM software 1134 provides, on the basis of the proposed tool pathoutput, a cutting conditions output, defining for each machiningoperation: tool engagement angles for each point along the trajectory,the feed speed at each point along the trajectory and the rpm. The CCMsoftware 1134 and/or the TPG software 1132 provide a UDC avoidance inputto MHBUCA module 1110 including for each machining operation: theWMTTMT, the depth of cut, and the rpm.

MHBUCA module 1110 consults HED database 1136, associated therewith,which contains the historical mappings indicating which pairings ofdepth of cut and rpm do not produce UDC for the given WMTT andpreferably also which pairings of depth of cut and rpm do produce UDCfor the given WMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 1110.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 1110,based on HED database 1136, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTT. Preferably, an rpm which is higher than the UDC-problematicrpm is selected, however, there may be instances where an rpm which islower than the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 1110, theproposed replacement rpm is output to the CCM software 1134, whichconfirms that the replacement rpm is suitable for use for the given WMTTunder the cutting conditions already established by the CCM software1134 for the given operation. This confirmation is provided by the CCMsoftware 1134 to the MCNCPG software 1130, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller1122 of a given machine tool, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 1134 is not provided, the MCNCPG software 1130provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 1110.

MHBUCA module 1110 consults HED database 1136, associated therewith,which contains the historical mappings indicating which pairings ofdepth of cut and rpm do not produce UDC for the given WMTT andpreferably also which pairings of depth of cut and rpm do produce UDCfor the given WMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 1110.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 1110,based on HED database 1136, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTT. Preferably, an rpm which is higher than the UDC-problematicrpm is selected, however, there may be instances where an rpm which islower than the UDC-problematic rpm is selected.

Additionally or alternatively, where multiple machine tools having atleast somewhat different characteristics are suitable and available fora given machining operation for a given WMTT and where the historicalempirical data (HED) database 1136 contains multiple HUPA maps 1195corresponding to different available machine tools, the MHBUCA module1110 may select one or more specific machine tools from among all of thesuitable and available machine tools to carry out the machiningoperation. Furthermore, the MHBUCA module 1110 may select one or morespecific machine tools from among all of the suitable and availablemachine tools which will carry out the given machining operation in anoptimal manner not only from the perspective of UDC avoidance but alsofrom the perspective of machining efficiency, such as machining cycletime.

Where a change in the rpm is proposed by the MHBUCA module 1110, theproposed replacement rpm is output to the MCNCPG software 1130, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 1130 provides a final UDC-free CNC program ready for loadingonto the CNC controller 1122 prior to commencement of machining.

It is appreciated that this embodiment of the present invention operatesinitially in a learning mode wherein most of the pixels in the HUPA maps1195, each representing a depth of cut and rpm pairing for a givenmachine, tool and workpiece material, are not yet marked as UDC orUDC-free pixels. In such cases, there are expected to be many situationsin which a proposed pair is neither validated nor disallowed and wherethe system carries out machining without a definite prediction regardingUDC. It will be appreciated by persons skilled in the art that thelikelihood that the system will be able to accurately predict whether ornot a given proposed non-marked pixel will be UDC-free depends on thedensity of marked pixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 1130 provides a final CNC program usingthe proposed pixel, ready for loading onto the CNC controller 1122 priorto commencement of machining.

It is a particular feature of the embodiment of the present inventiondescribed hereinabove with reference to FIG. 3B, that where the systemis unable to provide a UDC prediction based on machine tool specificHUPA maps 1195, it may well be able to provide a UDC prediction based onnon-machine tool specific HUPA maps 1195, which, being based on arelatively large number of machining events may be substantially morepopulated than corresponding machine tool specific HUPA maps 1195.

It is a particular feature of an embodiment of the present inventionthat various types of HUPA maps 1195 may be provided. These include, forexample:

-   -   A. a machine tool specific HUPA map 1195 which is based on        historical empirical data from a given machine tool;    -   B. a machine tool type specific HUPA map 1195, which is based on        historical empirical data received from multiple machine tools        of a given type;    -   C. a machine tool manufacturer specific map 1195, which is based        on historical empirical data received from multiple machine        tools made by a given manufacturer;    -   D. a machine tool characteristic specific map 1195, which is        based on historical empirical data received from multiple        machine tools having at least one given structural or        operational characteristic.

Various additional types of HUPA maps 1195 may be additionally oralternatively provided.

It is appreciated that type A HUPA maps 1195 are the most reliable forUDC prediction for the given machine tool to which they relate and thattypically type B—type D HUPA maps 1195 are typically less reliable forUDC prediction. Accordingly normally MHBUCA module 1110 will inquire asto whether a pixel associated with a given depth of cut/rpm is indicatedto be UDC free on the type A HUPA map 1195 relating to the given machinetool. If a pixel associated with a given depth of cut/rpm is indicatedto be UDC free on the type A HUPA map 1195, no further inquiry isrequired.

If however, the historical map generator 1190 is at a relatively earlylearning phase with respect to the relevant type A HUPA map 1195 andthus a pixel associated with a given depth of cut/rpm and pixels havingsimilar rpms for the same depth of cut are not indicated to be UDC freeon the type A HUPA map 1195, the MHBUCA module 1110 may consider HUPAmaps 1195 of types B, C and D or other suitable HUPA maps 1195.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software1130 in CNCPGCAM server 1120, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 1195, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 1195 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 1195 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 1195, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

Reference is now made to FIG. 3C, which is a simplified illustration ofa milling CNC program generation CAM and CNC milling system andmethodology employing a multiplicity of machine tools, typically ofvarious different types, and preferably including at least one millinghistory-based undesirable chatter avoidance module resident on at leastone CNC program generation CAM server, which is located on the cloud.

FIG. 3C shows a milling CNC program generation CAM and CNC millingsystem 1200 and methodology employing a large number of machine tools,typically of different types, made by different manufacturers and heredesignated by reference numerals 1201, 1202, 1203, 1204, 1205, 1206,1207, 1208, and 1209. The machine tools are distributed over amultiplicity of workshops, which are located geographically throughoutthe world. In one realization of this embodiment of the invention, themachine tools are all managed by a single organization, such as, forexample, an aircraft manufacturing company, which manufactures aircraftparts in multiple facilities throughout the world. In anotherrealization of this embodiment of the invention the machine tools aremanaged by different entities.

System 1200 preferably comprises one or more milling history-basedundesirable chatter avoidance (MHBUCA) modules 1210, constructed andoperative in accordance with one embodiment of the present invention,preferably resident on one or more CNCPGCAM servers 1220 located on thecloud. The one or more CNCPGCAM servers 1220 each provide a CNC programwhich is supplied from the cloud to at least one CNC controller 1222 ofone or more CNC milling machines, such as machining centers 1224. TheCNC program preferably includes, inter alia, a tool path, spindle on/offcommands, tool change commands, rpm commands, feed commands and coolanton/off commands.

In one realization of this embodiment of the invention, eachorganization may have one or more MHBUCA module 1210 and correspondingCNCPGCAM servers 1220 on the cloud, which receive empirical data onlyfrom machine tools managed by that organization. In another realizationof this embodiment of the invention one or more MHBUCA modules 1210 andcorresponding CNCPGCAM servers 1220 may be provided on the cloud and mayreceive empirical data from machine tools of more than one organizationor entity.

In a further realization of this embodiment of the invention, which isnot mutually exclusive to the realizations described in the precedingparagraph, each organization may have one or more MHBUCA module 1210 andcorresponding CNCPGCAM servers 1220, which may provide NMTSHUPA maps foruse by machine tools managed by that organization. In another furtherrealization of this embodiment of the invention, which is not mutuallyexclusive to the realizations described in the preceding paragraph, oneor more MHBUCA modules 1210 and corresponding CNCPGCAM servers 1220 maybe provided, which may provide NMTSHUPA maps for use by machine tools ofmore than one organization or entity.

Each CNCPGCAM server 1220 may be any suitable CNC program generation CAMserver and is preferably a server hosting milling CNC program generation(MCNCPG) software 1230. The MCNCPG software 1230 preferably includestool path generation (TPG) software 1232 and cutting conditionsmanagement (CCM) software 1234.

A preferred type of MCNCPG software 1230 is Solidcam™ milling CNCprogram generation software and includes cutting conditions managementsoftware 1234 embodied in an IMACHINING® module, which provides anoutput including a set of cutting conditions suitable for each pointalong a given toolpath. Solidcam™ milling CNC program generationsoftware is commercially available from the assignee of the presentapplication, SolidCAM Ltd. of Or-Yehuda, Israel.

Aspects of the structure and operation of the IMACHINING® module aredescribed and claimed in U.S. Pat. Nos. 8,489,224 and 9,052,704 and U.S.Patent Publication No. 2013/0345853, the disclosures of which are herebyincorporated by reference.

The system of FIG. 3C is described hereinbelow with reference to CNCmachining centers, it being understood that it is at least partiallyapplicable to other types of CNC machine tools, such as mill/turnmachines.

In accordance with a preferred embodiment of the present invention,MHBUCA module 1210 stores and utilizes pairs of depth of cut and rpm atwhich undesirable chatter (UDC) did not occur for past machining, usingat least one given type of milling machine, at least one given type ofcutting tool and at least one given type of workpiece material, and thusprovides undesirable chatter (UDC) avoidance as part of the CNC programgeneration.

In the embodiment of FIG. 3C, the MCNCPG software 1230 and CNCPGCAMserver 1220 are located on the cloud and are accessed by productionengineers using suitable communication devices 1235, such as smartphonesor pads or notebook computers, to generate the CNC programs which aredownloaded from the cloud to the controller of each one of multiple CNCmachine tools.

In accordance with this embodiment of the invention, the MHBUCA module1210 employs empirical data obtained from machining activity carried outon multiple machines, at various disparate locations, on at least oneworkpiece material at an earlier time, which data is stored in at leastone historical empirical data (HED) database 1236, to generate and storehistorical mappings indicating which pairings of depth of cut and rpmproduce or do not produce tool undesirable chatter (UDC) when at leastone given type of tool is used to machine at least one given type ofworkpiece material. It is a particular feature of an embodiment of thepresent invention that the MHBUCA module 1210 stores and utilizes pairsof depth of cut and rpm at which undesirable chatter (UDC) did not occurfor past machining, using at least one given type of milling machine, atleast one given type of cutting tool and at least one given type ofworkpiece material, in providing chatter avoidance.

In one realization of this embodiment, each MHBUCA module 1210 receivesempirical data originating from machines all belonging to a singleorganization. In another realization of this embodiment, at least oneMHBUCA module 1210 receives empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboverealizations, each MHBUCA module 1210 receives empirical dataoriginating from machines of the same type, manufactured by a samemanufacturer or alternatively receives empirical data from machines ofdifferent types, manufactured by a same manufacturer. As a furtheralternative, at least one MHBUCA module 1210 receives empirical datafrom machines of different types, manufactured by differentmanufacturers.

In the illustrated embodiment of FIG. 3C, the historical empirical datais derived from earlier operation of one or more CNC machining center1224 and is employed to generate subsequent UDC-free CNC programs forone or more CNC machining center 1224, such that milling operation ofthe CNC machining centers 1224 based on the CNC programs thus generatedavoids UDC.

In accordance with a preferred embodiment of the invention, one or moremicrophone 1260 is mounted on each CNC machining center 1224, such aswithin the machining chamber 1262 of the CNC machining center 1224 or onan outer housing thereof. Each CNC machining center 1224 also typicallyincludes CNC controller 1222 An output of microphone 1260 is supplied tomicrophone input circuitry 1270, which may include spectral analysisfunctionality 1272, such as Fast Fourier Transformation (FFT)functionality, which transforms the microphone output, which is in thetime domain, to the frequency domain.

An output of the microphone input circuitry 1270, which preferablyincludes the spectral analysis functionality 1272, is in the frequencydomain and is supplied to a UDC identifier 1280 which identifies peaksin the frequency domain, which are not coincident with any of theharmonic peaks characteristic of the tooth passing frequency. If suchpeaks exceed a given height, corresponding to a predetermined amplitudethreshold characterizing UDC, the presence of UDC is identified.

In accordance with one embodiment of the invention, microphone inputcircuitry 1270, spectral analysis functionality 1272 and UDC identifier1280 may be provided at each machine tool. Alternatively, the microphoneinput circuitry 1270 may be provided at each machine tool and thespectral analysis functionality 1272 and UDC identifier 1280 may beprovided as part of at least one MHBUCA module 1210. As a furtheralternative, microphone input circuitry 1270, spectral analysisfunctionality 1272 and UDC identifier 1280 may all be provided as partof at least one MHBUCA module 1210.

A historical map generator 1290 receives a UDC presence input from atleast one UDC identifier 1280 having a time stamp and also receives,from the CNC controller 1222 of the corresponding CNC machining center1224, at least one input providing current information indicating thetool currently being used in milling, the workpiece material beingmilled, the current depth of cut and the current rpm. On the basis ofthe aforesaid inputs, the historical map generator 1290 creates aplurality of historical UDC presence/absence (HUPA) maps 1300. It is aparticular feature of an embodiment of the present invention that theHUPA maps 1300 include depth of cut and rpm pairs for most or allinstances where UDC did not occur. Preferably, but not necessarily, theHUPA maps 1300 also include depth of cut and rpm pairs for most or allinstances where UDC did occur.

In accordance with one embodiment of the invention, historical mapgenerator 1290 receives a UDC presence input from at least one UDCidentifier 1280 based on empirical data originating from machines allbelonging to a single organization. In another embodiment, historicalmap generator 1290 receives a UDC presence input from at least one UDCidentifier 1280 based on empirical data originating from various typesof machine tools belonging to multiple organizations and entities. Inboth of the above embodiments, historical map generator 1290 receives aUDC presence input from at least one UDC identifier 1280 based onempirical data originating from machines of the same type, manufacturedby a same manufacturer, or, alternatively, based on empirical data frommachines of different types, manufactured by a same manufacturer. As afurther alternative, historical map generator 1290 receives a UDCpresence input from at least one UDC identifier 1280 based on empiricaldata from machines of different types, manufactured by differentmanufacturers.

In accordance with an embodiment of the present application, each HUPAmap 1300 is specific at least to a given combination of workpiecematerial and type of tool, here designated WMTT.

In accordance with one embodiment of the invention, at least one HUPAmap 1300 is based on empirical data originating from machines allbelonging to a single organization. In another embodiment, at least oneHUPA map 1300 is based on empirical data originating from machinesbelonging to multiple organizations and entities. In both of the aboveembodiments, at least one HUPA map 1300 is based on empirical dataoriginating from machines of the same type, manufactured by a samemanufacturer or alternatively based on empirical data from machines ofdifferent types, manufactured by a same manufacturer. As a furtheralternative, at least one HUPA map 1300 is based on empirical data frommachines of different types, manufactured by different manufacturers.

In accordance with one embodiment of the invention, similarly to thecase described above with reference to FIGS. 1A-1C, each HUPA map 1300is machine tool specific as well and thus HUPA maps 1300 are generatedfor each of the multiple machine tools communicating with the system.This is particularly relevant when the various CNC machining centers1224 are of different types or have different overall operatingcharacteristics, which render them suitable for different machiningtasks. In such a case, the generation of machine tool specific HUPA maps1300 is useful in enabling production planning and allocation ofmachining resources. The tool specific HUPA maps 1300 are each based onempirical data relating to a combination of workpiece material, type oftool and machine tool, here designated WMTTMT.

In accordance with another embodiment of the invention, as distinguishedfrom the case described above with reference to FIGS. 1A-1C, non-machinetool specific HUPA (NMTSHUPA) maps 1300 may be generated based onempirical data received from multiple machine tools having at least apredetermined level of similarity. For example, the multiple machinetools whose empirical data is used for generating a NMTSHUPA map 1300may be manufactured by different manufacturers but have the same powerand speed capabilities. In another example, the multiple machine toolswhose empirical data is used for generating a NMTSHUPA map 1300 may bemanufactured by the same manufacturer and have similar mechanicalstructures but have different spindle ratings. In a further example, themultiple machine tools whose empirical data is used for generating aNMTSHUPA map 1300 may be manufactured by the same manufacturer ordifferent manufacturers and have similar mechanical structures,rigidity, and ranges of movements along their various axes.

It is appreciated that separate NMTSHUPA maps 1300 may be generated fora given WMTT based on various additional parameters including, forexample, a level of tool wear or a different threshold applicable to thedefinition of UDC. It is further appreciated that even more specificNMTSHUPA maps 1300 may be generated for a given WMTT for eachcombination of a plurality of selectable machining parameters, forexample, the corner radius of each cutting edge, the rake angle of eachcutting edge, the flute helix angle of each cutting edge, the number oflayers of inserts in an insert cutter, the number of inserts in eachlayer, the dimensions of each insert and the extent of overlap betweenlayers of inserts.

It is appreciated that preferably, the NMTSHUPA maps 1300 are built upbased on actual recorded microphone inputs from actual past machiningoperations on multiple workpieces. Thus, similarly to that describedhereinabove with reference to FIG. 4 , initially only a few pixels,representing specific depth of cut and rpm pairings, appear, heretypically represented by a black solid pixel indicating the absence ofUDC and preferably also by a cross-hatched pixel indicating the presenceof UDC. These pairings represent actual depth of cut and rpm pairings ofhistorical machining operations for a given type of tool and materialusing one or more CNC machining centers 1224.

Over time, as more and more actual depth of cut and rpm pairings areutilized in actual machining carried out by CNC machining centers 1224,more and more pixels in each HUPA map 1300 are filled in, typically by ablack solid pixel indicating the absence of UDC or by a cross-hatchedpixel indicating the presence of UDC. The latest NMTSHUPA map 1300 foreach different WMTT is preferably stored in HED database 1236 and isautomatically consulted by the MCNCPG software 1230, such as theIMACHINING® software, to validate the acceptability of the CNC programgenerated thereby.

A preferred methodology for this consultation is briefly summarizedbelow:

-   -   The MCNCPG software 1230 initially proposes a depth of cut/rpm        pair;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 1230 corresponds to a black solid pixel, indicating        that historically UDC was not encountered, the depth of cut/rpm        pair is validated;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 1230 corresponds to a cross-hatched pixel, indicating        that historically UDC was encountered, the depth of cut/rpm pair        is disallowed;    -   If the depth of cut/rpm pair initially proposed by the MCNCPG        software 1230 does not correspond to a black solid pixel, which        black solid pixel indicates that historically UDC was not        encountered, and if the depth of cut/rpm pair initially proposed        by the MCNCPG software 1230 does not correspond to a        cross-hatched pixel, which cross-hatched pixel indicates that        historically UDC was encountered, a first order neighborhood        analysis is preferably performed, whereby it is ascertained        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 1230 are black solid        pixels, if so, the initially proposed depth of cut/rpm pair is        validated;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair, then        the first order neighborhood analysis also preferably ascertains        whether all of the pixels immediately contiguous to the four        sides of the pixel representing the depth of cut/rpm pair        initially proposed by the MCNCPG software 1230 are cross-hatched        pixels. If so, the depth of cut/rpm pair initially proposed by        the MCNCPG software 1230 is disallowed;    -   If the first order neighborhood analysis described above did not        result in validating the proposed depth of cut/rpm pair and did        not result in disallowing the proposed depth of cut/rpm pair,        the first order neighborhood analysis preferably also ascertains        if a predetermined number, less than all, or one or more        predetermined configurations of the pixels immediately        contiguous to the four sides of the pixel representing the depth        of cut/rpm pair initially proposed by the MCNCPG software 1230        are cross-hatched pixels. If so, the depth of cut/rpm pair        initially proposed by the MCNCPG software 1230 is disallowed. In        an alternative embodiment, if the first order neighborhood        analysis described above did not result in validating the        proposed depth of cut/rpm pair and did not result in disallowing        the proposed depth of cut/rpm pair, the first order neighborhood        analysis preferably ascertains if a predetermined number, less        than all, or one or more predetermined configurations of the        pixels immediately contiguous to the four sides of the pixel        representing the depth of cut/rpm pair initially proposed by the        MCNCPG software 1230 are not cross-hatched pixels. If so, the        depth of cut/rpm pair initially proposed by the MCNCPG software        1230 is not disallowed.

In a situation where the depth of cut/rpm pair proposed by the MCNCPGsoftware 1230 is neither validated nor disallowed, the system mayproceed along one of the following operational paths:

1. Proceed to machine the workpiece using the depth of cut/rpm pairproposed by the MCNCPG software 1230; or

2. Perform further analysis of the depth of cut/rpm pair proposed by theMCNCPG software 1230.

One example of possible further analysis is performing additionalneighborhood analyses as described hereinbelow:

If the first order neighborhood analysis described above does not resultin validation or disallowing of the initially proposed depth of cut/rpmpair, a next order neighborhood analysis is preferably performed,whereby it is ascertained whether all of the pixels separated by onepixel from the initially proposed depth of cut/rpm pair are black solidpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software1230 is validated.

If the next order neighborhood analysis does not result in validation ofthe depth of cut/rpm pair proposed by the MCNCPG software 1230, it isascertained whether all or at least a predetermined number or one ormore predetermined configurations of the pixels separated by one pixelfrom the initially proposed depth of cut/rpm pair are cross-hatchedpixels. If so, the depth of cut/rpm pair proposed by the MCNCPG software1230 is disallowed.

If the aforesaid further analysis does not result in either validationor disallowing of the depth of cut/rpm pair proposed by the MCNCPGsoftware 1230, preferably the system proceeds to machine the workpieceusing the depth of cut/rpm pair proposed by the MCNCPG software 1230.

More specifically, in accordance with a preferred embodiment of thepresent invention wherein CCM software 1234 is provided, the TPGsoftware 1232 provides a proposed tool path output, defining for eachmachining operation: particulars of the tool, the depth of cut, thenominal feed speed and the tool trajectory, to the CCM software 1234.The CCM software 1234 provides, on the basis of the proposed tool pathoutput, a cutting conditions output, defining for each machiningoperation: tool engagement angles for each point along the trajectory,the feed speed at each point along the trajectory and the rpm. The CCMsoftware 1234 and/or the TPG software 1232 provide a UDC avoidance inputto MHBUCA module 1210 including for each machining operation: theWMTTMT, the depth of cut, and the rpm.

MHBUCA module 1210 consults HED database 1236, associated therewith,which contains the historical mappings indicating which pairings ofdepth of cut and rpm do not produce UDC for the given WMTT andpreferably also which pairings of depth of cut and rpm do produce UDCfor the given WMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 1210.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 1210,based on HED database 1236, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTT. Preferably, an rpm which is higher than the UDC-problematicrpm is selected, however, there may be instances where an rpm which islower than the UDC-problematic rpm is selected.

Where a change in the rpm is proposed by the MHBUCA module 1210, theproposed replacement rpm is output to the CCM software 1234, whichconfirms that the replacement rpm is suitable for use for the given WMTTunder the cutting conditions already established by the CCM software1234 for the given operation. This confirmation is provided by the CCMsoftware 1234 to the MCNCPG software 1230, which provides a final,UDC-free CNC program output ready for loading onto the CNC controller1222 of a given machine tool, prior to commencement of machining.

In accordance with another preferred embodiment of the present inventionwherein CCM software 1234 is not provided, the MCNCPG software 1230provides a proposed CNC program output, defining for each machiningoperation: the WMTTMT, the depth of cut, the rpm, the feed speeds andthe tool trajectory in response to a user-defined nominal cuttingconditions input, defining for each machining operation along a proposedtool trajectory: nominal tool engagement angle, nominal feed speed,depth of cut and rpm.

The particulars of the WMTT, the depth of cut and the rpm are suppliedas a UDC avoidance input to MHBUCA module 1210.

MHBUCA module 1210 consults HED database 1236, associated therewith,which contains the historical mappings indicating which pairings ofdepth of cut and rpm do not produce UDC for the given WMTT andpreferably also which pairings of depth of cut and rpm do produce UDCfor the given WMTT.

If the pairings of depth of cut and rpm did not historically produce UDCfor the given WMTT, or are validated as described hereinabove, no changein the rpm is made by MHBUCA module 1210.

If the pairings of depth of cut and rpm did historically produce UDC forthe given WMTT, or are disallowed as described above, the rpm isconsidered to be UDC-problematic for the indicated depth of cut.Accordingly, a change in the rpm is proposed by MHBUCA module 1210,based on HED database 1236, which contains the historical mappingsindicating which pairings of depth of cut and rpm did not historicallyproduce UDC for the given WMTT and preferably also indicating whichpairings of depth of cut and rpm did historically produce UDC for thegiven WMTT. Preferably, an rpm which is higher than the UDC-problematicrpm is selected, however, there may be instances where an rpm which islower than the UDC-problematic rpm is selected.

Additionally or alternatively, where multiple machine tools having atleast somewhat different characteristics are suitable and available fora given machining operation for a given WMTT and where HED database 1236contains multiple HUPA maps 1300 corresponding to different availablemachine tools, the MHBUCA module 1210 may select one or more specificmachine tools from among all of the suitable and available machine toolsto carry out the machining operation. Furthermore, the MHBUCA module1210 may select one or more specific machine tools from among all of thesuitable and available machine tools which will carry out the givenmachining operation in an optimal manner not only from the perspectiveof UDC avoidance but also from the perspective of machining efficiency,such as machining cycle time.

Where a change in the rpm is proposed by the MHBUCA module 1210, theproposed replacement rpm is output to the MCNCPG software 1230, andpreferably the operator confirms that the replacement rpm is suitablefor use by the given tool and the given machine under the cuttingconditions already established for the given operation. The MCNCPGsoftware 1230 provides a final UDC-free CNC program ready for loadingonto the CNC controller 1222 prior to commencement of machining.

It is appreciated that this embodiment of the present invention operatesinitially in a learning mode wherein most of the pixels in the HUPA maps1300, each representing a depth of cut and rpm pairing for a givenmachine, tool and workpiece material, are not yet marked as UDC orUDC-free pixels. In such cases, there are expected to be many situationsin which a proposed pair is neither validated nor disallowed and wherethe system carries out machining without a definite prediction regardingUDC. It will be appreciated by persons skilled in the art that thelikelihood that the system will be able to accurately predict whether ornot a given proposed non-marked pixel will be UDC-free depends on thedensity of marked pixels in the vicinity of the proposed pixel.

If the system predicts that the proposed pixel will be a UDC pixel, thesystem automatically searches for a suitable UDC-free pixel as describedabove. If the system predicts that the proposed pixel will be a UDC-freepixel, or if the proposed depth of cut/rpm pair is neither validated nordisallowed, the MCNCPG software 1230 provides a final CNC program usingthe proposed pixel, ready for loading onto the CNC controller 1222 priorto commencement of machining.

It is a particular feature of the embodiment of the present inventiondescribed hereinabove with reference to FIG. 3C, that where the systemis unable to provide a UDC prediction based on machine tool specificHUPA maps 1300, it may well be able to provide a UDC prediction based onnon-machine tool specific HUPA maps 1300, which, being based on arelatively large number of machining events may be substantially morepopulated than corresponding machine tool specific HUPA maps 1300.

It is a particular feature of an embodiment of the present inventionthat various types of HUPA maps 1300 may be provided. These include, forexample:

-   -   A. a machine tool specific HUPA map 1300 which is based on        historical empirical data from a given machine tool;    -   B. a machine tool type specific HUPA map 1300, which is based on        historical empirical data received from multiple machine tools        of a given type;    -   C. a machine tool manufacturer specific HUPA map 1300, which is        based on historical empirical data received from multiple        machine tools made by a given manufacturer;    -   D. a machine tool characteristic specific HUPA map 1300, which        is based on historical empirical data received from multiple        machine tools having at least one given structural or        operational characteristic.

Various additional types of HUPA maps 1300 may be additionally oralternatively provided.

It is appreciated that type A HUPA maps 1300 are the most reliable forUDC prediction for the given machine tool to which they relate and thattypically type B—type D HUPA maps 1300 are typically less reliable forUDC prediction. Accordingly, normally MHBUCA module 1210 will inquire asto whether a pixel associated with a given depth of cut/rpm is indicatedto be UDC free on the type A HUPA map 1300 relating to the given machinetool. If a pixel associated with a given depth of cut/rpm is indicatedto be UDC free on the type A HUPA map 1300, no further inquiry isrequired.

If however, the historical map generator 1290 is at a relatively earlylearning phase with respect to the relevant type A HUPA map 1300 andthus a pixel associated with a given depth of cut/rpm and pixels havingsimilar rpms for the same depth of cut are not indicated to be UDC freeon the type A HUPA map 1300, the MHBUCA module 1210 may consider HUPAmaps 1300 of types B, C and D or other suitable HUPA maps 1300.

When UDC occurs during machining, machining is automatically andimmediately stopped and a new rpm is calculated by the MCNCPG software1230 in CNCPGCAM server 1220, which rpm is believed, based on theinformation in the most up to date relevant HUPA map 1300, to avoid UDC.

In cases where UDC does not occur for machining at a given depth of cutand rpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 1300 for that machine,tool and workpiece material is typically marked as a black solid pixel,to indicate that UDC did not occur during machining at that given depthof cut and rpm.

In cases where UDC does occur for machining at a given depth of cut andrpm pairing for a given machine, tool and workpiece material, acorresponding pixel in an appropriate HUPA map 1300 for that machine,tool and workpiece material is typically marked as a cross-hatchedpixel, to indicate that UDC did occur during machining at that givendepth of cut and rpm.

It will be appreciated by persons skilled in the art that the ongoingoperation of the system enhances the learning of the system and fills inthe pixels in the HUPA maps 1300, thus increasing the effectiveness ofthe system in predicting and thus avoiding UDC.

It will be appreciated by persons skilled in the art that the presentinvention is not limited by what is particularly shown and describedhereinabove and includes combinations and subcombinations of variousfeatures described herein as well as modifications thereof, which arenot in the prior art.

1. A computerized method of machining a workpiece comprising: employingan historical mapping, based on empirical data obtained from machiningactivity at an earlier time, said an historical mapping indicating:pairings of depth of cut and rpm at which undesirable chatter (UDC) didnot occur during machining activity at an earlier time using at leastone given type of milling machine, at least one given type of cuttingtool and at least one given type of workpiece material; and pairings ofdepth of cut and rpm at which undesirable chatter (UDC) did occur duringmachining activity at an earlier time using said at least one given typeof milling machine, said at least one given type of cutting tool andsaid at least one given type of workpiece; prior to commencing machiningof said workpiece, programming a machine tool to machine said workpieceusing one of said at least one given type of milling machine, one ofsaid at least one given type of cutting tool and one of said at leastone given type of workpiece material at at least one depth of cut andrpm, which, based on said historical mapping, avoid undesirable chatter,said programming comprising ascertaining a suitable rpm for a givendepth of cut which will not create UDC by: employing a first pluralityof known pairings of depth of cut and rpm, which are known from saidhistorical mapping for said given type of milling machine, said giventype of cutting tool and said given type of workpiece material not tocreate UDC; and employing a second plurality of known pairings of depthof cut and rpm, which are known from said historical mapping for saidgiven type of milling machine, said given type of cutting tool and saidgiven type of workpiece material to create UDC; and operating saidmachine tool in accordance with said programming to machine saidworkpiece.
 2. (canceled)
 3. A computerized method of machining aworkpiece according to claim 1 and wherein said programming alsocomprises: employing a third plurality of known pairings of depth of cutand rpm, which are known from said historical mapping for said giventype of milling machine, said given type of cutting tool and said giventype of workpiece material to be within a predetermined neighborhood ofknown pairings known not to create UDC and not to be within apredetermined neighborhood of known pairings known to create UDC forsaid at least one given type of milling machine, said at least one giventype of cutting tool and said at least one given type of workpiecematerial, in order to ascertain a suitable rpm for a given depth of cutwhich will not create UDC.
 4. (canceled)
 5. A computerized method ofmachining a workpiece according to claim 3 and wherein said suitable rpmfor said given depth of cut need not correspond to one of said knownpairings.
 6. A computerized method of machining a workpiece according toclaim 3 and wherein said suitable rpm for said given depth of cut doesnot correspond to one of said known pairings. 7-8. (canceled)
 9. Acomputerized method of machining a workpiece according to claim 1 andwherein said programming also comprises: initially generating an initialCNC program for machining said workpiece without necessarily consideringUDC issues, said initial CNC program including at least one proposedpairing of depth of cut and rpm for at least one given type of millingmachine, at least one given type of cutting tool and at least one giventype of workpiece material; and validating said at least one proposedpairing, based on said historical mapping.
 10. A computerized method ofmachining a workpiece according to claim 1 and wherein said programmingalso comprises: initially generating an initial CNC program formachining said workpiece without necessarily considering UDC issues,said initial CNC program including at least one proposed pairing ofdepth of cut and rpm for at least one given type of milling machine, atleast one given type of cutting tool and at least one given type ofworkpiece material; disallowing at least one of said at least oneproposed pairing, based on said historical mapping; generating at leastone revised CNC program for machining said workpiece based on saidhistorical mapping, said initial CNC program including at least onealternative proposed pairing of depth of cut and rpm for at least onegiven type of milling machine, at least one given type of cutting tooland at least one given type of workpiece material; and validating saidat least one revised proposed pairing, based on said historical mapping.11-20. (canceled)
 21. A computerized system for machining a workpiece,said system comprising: an historic mapping generator operative, priorto machining said workpiece, to generate an historical mapping, based onempirical data obtained from machining activity at an earlier time,indicating: pairings of depth of cut and rpm at which undesirablechatter (UDC) did not occur during machining activity at an earlier timeusing at least one given type of milling machine, at least one giventype of cutting tool and at least one given type of workpiece material;and pairings of depth of cut and rpm at which undesirable chatter (UDC)did occur during machining activity at an earlier time using said atleast one given type of milling machine, said at least one given type ofcutting tool and said at least one given type of workpiece material; anda computerized machine tool programmer operative, prior to commencingmachining of said workpiece, to generate a machine tool program enablinga machine tool to machine said workpiece using one of said at least onegiven type of milling machine, one of said at least one given type ofcutting tool and one of said at least one given type of workpiecematerial at at least one depth of cut and rpm, which, based on saidhistorical mapping, avoid undesirable chatter, said computerized machinetool programmer comprising a suitable depth of cut and rpm ascertainer,said ascertainer operative to ascertain a suitable rpm for a given depthof cut which will not create UDC by: employing a first plurality ofknown pairings of depth of cut and rpm, which are known from saidhistorical mapping for said given type of milling machine, said giventype of cutting tool and said given type of workpiece material not tocreate UDC; and employing a second plurality of known pairings of depthof cut and rpm, which are known from said historical mapping for saidgiven type of milling machine, said given type of cutting tool and saidgiven type of workpiece material to create UDC; and a machine tooloperable in accordance with said programming to machine said workpiece.22. (canceled)
 23. A computerized system for machining a workpieceaccording to claim 21 and wherein said computerized machine toolprogrammer also comprises: a suitable depth of cut and rpm ascertainer,employing a third plurality of known pairings of depth of cut and rpm,which are known from said historical mapping for said given type ofmilling machine, said given type of cutting tool and said given type ofworkpiece material to be within a predetermined neighborhood of knownpairings known not to create UDC and not to be within a predeterminedneighborhood of known pairings known to create UDC for said at least onegiven type of milling machine, said at least one given type of cuttingtool and said at least one given type of workpiece material, in order toascertain a suitable rpm for a given depth of cut which will not createUDC.
 24. (canceled)
 25. A computerized system for machining a workpieceaccording to claim 23 and wherein said suitable rpm for said given depthof cut need not correspond to one of said known pairings.
 26. Acomputerized system for machining a workpiece according to claim 23 andwherein said suitable rpm for said given depth of cut does notcorrespond to one of said known pairings. 27-28. (canceled)
 29. Acomputerized system for machining a workpiece according to claim 21 andwherein said computerized machine tool programmer also comprises: aninitial CNC program generator, initially generating an initial CNCprogram for machining said workpiece without necessarily considering UDCissues, said initial CNC program including at least one proposed pairingof depth of cut and rpm for at least one given type of milling machine,at least one given type of cutting tool and at least one given type ofworkpiece material; and a proposed pairing validator, validating said atleast one proposed pairing, based on said historical mapping.
 30. Acomputerized system for machining a workpiece according to claim 21 andwherein said computerized machine tool programmer also comprises: aninitial CNC program generator, initially generating an initial CNCprogram for machining said workpiece without necessarily considering UDCissues, said initial CNC program including at least one proposed pairingof depth of cut and rpm for at least one given type of milling machine,at least one given type of cutting tool and at least one given type ofworkpiece material; a proposed pairing disallower, disallowing at leastone of said at least one proposed pairing, based on said historicalmapping; a revised CNC program generator, generating at least onerevised CNC program for machining said workpiece based on saidhistorical mapping, said initial CNC program including at least onealternative proposed pairing of depth of cut and rpm for at least onegiven type of milling machine, at least one given type of cutting tooland at least one given type of workpiece material; and a revisedproposed pairing validator, validating said at least one revisedproposed pairing, based on said historical mapping. 31-40. (canceled)